Posted on June 18, 2021 by Michael Boik

Custom Sized Recycled Mailer Envelopes

While we have long offered mailer envelopes as both an unprinted and printed packaging option for clothing/soft goods and apparel, our customers were limited to only 10 standard stock sizes. These stock mailers, though popular, did not allow for any variation for unique products or applications. However, as of December 2020, we were able to offer custom sized recycled mailer envelopes for the first time, and the interest has been booming.


The Benefits of Custom Sizes

Many of our stock mailer sizes are ideal for common applications, such as a single t-shirt or pair of jeans. But there are however, occasional applications that involve bulky or large items that simply won’t fit within our largest stock mailers, or perhaps a product that would be a better fit within a size that falls somewhere in between two of our stock sizes. Keep in mind also that all of our stock sizes open along the smaller dimension. So, for example, an 8.25 x 12 mailer will open along the 8.25’’ end. As a custom size, we can create a mailer that opens along the longer 12’’ side instead (ideal for cosmetics), which is known as a side-open design. We also offer expandable mailer options, so if you have a custom size in mind, with the need for a 3 or 4 inch expansion, we can make it happen. We can even do a 1’’ expansion, if you only need a bit more room than a standard flat mailer provides.

Another benefit of a custom mailer is that you can very easily add custom printing, or other options like a resealable lip strip to make the mailer reusable.

We do of course have a few limitations. There are certain sizes that would simply be too large for our equipment, or even too small in some cases. We typically also ask that your dimensions stay within half inch increments on the mailer body dimensions and full inch for the expansion dimension. But chances are we can very likely find a solution that works for your needs.


Custom Size Cost and Minimums

Unlike die cut mailer boxes, there is NO tooling cost to create a custom sized mailer envelope. This means potential savings of up to four-figures. It also means that order volume is important to offset the cost of creating a custom mailer from a manufacturing standpoint. The minimum for a custom size is always at least 5,000, and 10,000 for some sizes and applications. But you will see price discounts as your volume increases to 15,000, 20,000 and beyond to truly maximize your savings on a per unit basis. Again, keep in mind that for a custom mailer, adding printing/branding is very easy and adds minimal cost to you.


Please Contact Us Today

Want to know more about custom sized recycled mailer envelopes? As always, if you have any questions on any of our products or services, one of our branded packaging advisors is standing by to assist, with decades of experience behind them. Want to know more about custom packaging options? Please call us at 630-551-1700 or contact us via email at


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