Mailers

Use corrugated mailers when a formed box-like enclosure and rigid panels suit the product. Poly mailers work well for many flexible, non-fragile items, while padded and air-cushioned formats add different interior protection. Flat mailers and chipboard-supported envelopes can help keep compatible documents, prints or thin products from bending.

Choose mailing tubes for rolled materials and bottle shippers for compatible containers requiring defined separation. Decorative or branded presentation should remain secondary to fit, closure and protection.

Check whether the stated dimensions are inside, outside or usable dimensions, and measure the product after folding, wrapping or adding inserts. Leave room for thickness and closure engagement without creating excessive movement. Sharp corners, hardware and rigid edges may require a stronger wall, reinforcement or a carton rather than a flexible envelope.

Pressure-sensitive closures need clean, dry sealing surfaces and complete contact. A closure described as tamper-evident or moisture-resistant must be verified for the exact product and conditions. Test the completed pack for the route, and confirm carrier rules for thickness, machinability, liquids, alcohol, batteries, hazardous materials or other controlled contents.