Size range
Small Poly Mailers
At the small end of the range, the mailer is rarely the constraint. What decides the size is the pricing band your parcel lands in, and the fact that a small bag has almost no tolerance for a fold that went wrong.
This page compares the two small formats and covers the thing that separates them commercially: whether the parcel stays inside the thickness limits that small-parcel rates are built around.
From$0.30per unit, indicative — your quotation is priced against your own specification
Price small poly mailers
A short brief is enough to start. We come back with a written specification and a price.
Thickness usually decides the size, not width
Most small-parcel rates are built around a depth limit as much as a footprint. A parcel that stays under that depth travels on one rate; the same contents in a bag that lets them bunch up travels on a higher one.
That is why a slightly larger mailer sometimes costs less to ship. A 9x12 lets a folded item lie flat and thin. The same item forced into a 6x9 becomes a compact lump — smaller in footprint, thicker in section, and on the wrong side of the threshold.
The practical test is not whether it fits. It is whether the packed parcel is flat.
The two small formats side by side
Both are cheap per unit and both store easily. What separates them is how much fold tolerance you get.
| Row label | 6x9 | 9x12 |
|---|---|---|
| Suits | One small item plus a card | One folded garment or a small bundle |
| Fold tolerance | None to speak of | A fold of slack |
| Keeps the parcel flat | Only for genuinely flat contents | For most single soft items |
| Print panel | Logo mark | Logo plus a short message |
| Units per carton | Highest | High |
| Common buyers | Jewelry, beauty, accessories | Apparel, books, prints |
Where small mailers go wrong
Ordering the smallest size to save on film
The film saving is pennies. If the tighter size makes the parcel thicker, the shipping cost outweighs it many times over.
Forgetting the insert
The thank-you card, the sticker sheet and the returns slip take up real space. Size against the full order, not the product alone.
Using a small mailer for anything with a hard edge
A boxed item in a tight bag puts a corner directly against the film. Either size up or use a cushioned format.
Assuming a small panel can carry a full brand lock-up
A wordmark, a strap line and social handles will not read at this size. One mark, sized properly, does more.
Options across the small formats
These apply to both sizes; the specification is confirmed on your quotation.
| Option | Choices | What changes |
|---|---|---|
| Film weight |
| Small parcels rarely need heavy film unless the contents have hard corners. |
| Closure |
| A tear tab is worth adding for gift and subscription ranges, where the opening is part of the experience. |
| Colour |
| Small formats are where coloured film gives the most impact for the least cost. |
| On a small panel, one side printed well usually beats two sides printed tightly. |
Options shown are the choices we can quote against. The exact specification for your order — including film weight, closure and print method — is confirmed in writing on your quotation.
Where colour does the most work
Small parcels arrive in a stack of other small parcels, and colour is what separates yours from the rest before anything is opened. It is also the cheapest form of branding available, because a coloured film costs far less than a printed run. The full range and how colour behaves against print is set out on the colour options across the mailer range, which covers contrast and print legibility on each base colour.
Questions about small poly mailers
Which small poly mailer size should I order?
Pack a real order, including the card and the returns slip, and pick the size that lets it lie flat. Flatness matters more than footprint, because parcel thickness is what most small-parcel rates are built around.
Are small poly mailers strong enough on their own?
For soft or boxed-but-light contents, yes. What small mailers do not do is absorb impact. If the contents are fragile, a cushioned format is the right choice rather than a heavier plain film.
Can small mailers be printed in full colour?
Yes. The limit is legibility rather than the process. Fine type and hairline details close up on flexible film, so it is worth checking small artwork with us before the run.
Do you supply small mailers unprinted?
Yes. Plain stock in a range of colours is available, and a lot of businesses start there while artwork is being finalised.
Settle the small-size question
Tell us what goes in the parcel, including the inserts. We will recommend a size and quote it, and send samples if that helps you decide.