Mail Guide: 3 Tips To Help You Pick the Right Size Mailer

Preparing products for shipping requires sturdy mailers that are capable of securing the contents during the entire shipping journey. Sizing is one of the main factors that you should consider when picking the best mailer for shipping. If you haven’t given this too much thought, this guide may change the way you choose your mailers.

Why Mailer Size Matters

What difference does it make if you choose to mail a small product in a large mailer or vice versa?

Well, it can mean the difference between a product that arrives in good condition versus damaged condition. As a rule of thumb, you should pick a mailer size that is closest in measurements to the product being shipped. An oversize mailer has too much space, causing the product to slide around. And you're paying extra for a large mailer that you don't need. Alternatively, a mailer that is too small will likely tear, exposing the item to the elements.

However, it's important to make allowances for product thickness and get a larger size if necessary.

Calculate Mailer Width Minimum

Keep a tape measure handy so you can quickly take product measurements. We recommend using formulas that help you make calculations faster. Let's start with the mailer width formula.

Product width + product height + 1/4-inch = minimum mailer width.

Getting the width right minimizes product sliding.

Calculate Mailer Length Minimum

You now need to know the length of the product. This formula helps you calculate length.

Product length + product height + product height + 1/4-inch = minimum mailer length.

Notice that product height is added twice. This is done to allow a flat mailer to expand to accommodate three-dimensional items. Knowing the length also helps ensure that you can easily insert the item into the mailer, leaving only a small bit of room for shifting.

Picking the Right Mailer Type and Size

Now that you have the two formulas for calculating mailer dimensions, you can move on to picking the best type of mailer for the item. Mailers can be made of different materials, and this can have an impact on how the product fits or moves inside it.

Bubble Mailer

This mailer's fun name describes what you see when you open it up and look inside. Typically, this mailer is a kraft envelope that has an inner lining made of plastic formed into rows of "bubbles" that provide a soft, yet firm, cushion for items placed inside.

Corrugated Mailers

The corrugated mailer is constructed of strong cardboard and designed as a box that comes in a variety of sizes. Most of these mailers can be used to mail such items as artwork, books and documents. Unlike other types of mailers, these come in flat bundles and need to be assembled before using.

Poly Mailers

Poly mailers are made from polyethylene, a flexible and durable material that also offers protection from dirt, dust and moisture. They are typically used for mailing soft items, such as clothing. To make them suitable for other items, you should wrap the items in bubble padding before inserting them into the mailers.