Poly Mailers vs Bubble Mailers – Which Is Best for Your Business?

Choosing the right packaging for online orders isn’t just about looks – it directly affects your margins and customer satisfaction. Pick the wrong mailer and you risk paying higher postage, receiving complaints about damaged goods or generating unnecessary waste. In this guide we compare poly mailers vs bubble mailers for UK e‑commerce sellers. You’ll learn the pros and cons of each, how they affect shipping costs and Royal Mail pricing, which products they suit best and how to choose eco‑friendly options. We’ll also explain why ePackaging Direct is the trusted supplier for businesses that want bulk discounts, no minimum order requirements and next‑day delivery across the UK.

What are poly mailers?

Key features of poly mailers

• Water‑resistant and tear‑resistant: Polyethylene is inherently waterproof, so poly mailers keep moisture out and resist tearing during transit.
• Self‑seal adhesive strip: Most poly mailers have a peel‑and‑seal flap, making packing fast and removing the need for additional tape. The seal also provides a tamper‑evident closure.
• Flexible and space‑saving: Because poly mailers are thin and pliable, they hug the contents and take up minimal storage space, both in your warehouse and in delivery vehicles.
• Customisable: Poly mailers can be printed in a range of colours or with logos, making them an affordable branding tool for SMEs.
• Low cost: Poly mailers are inexpensive to purchase and, because they weigh so little, reduce postage costs compared with padded mailers or boxes.

Best products for poly mailers

Poly mailers are ideal for soft and durable items such as clothing, textiles, accessories, fabrics, bedding, lightweight shoes and some electronics accessories. They provide enough protection for goods that aren’t fragile or prone to breaking. Retailers often choose poly mailers when they need to ship large volumes economically, when the products aren’t likely to be crushed or damaged by minor impacts, or when packaging needs to stay within Royal Mail’s cheaper Large Letter pricing band (discussed later).

What are bubble mailers?

Bubble mailers – also called bubble‑lined padded envelopes – consist of an outer layer of paper or plastic and an inner layer of bubble wrap. The bubbles provide cushioning to protect delicate items from shocks and punctures. A product listing for DVD bubble mailers notes that the mailer walls are lined with a 3/16‑inch bubble layer; the bubbles retain air to create cushioning and the air cellular lining surrounds the DVD box. The mailers also feature a peel‑and‑seal closure and are water‑resistant.

Key features of bubble mailers

• Cushioning and shock absorption: The bubble wrap lining absorbs impacts and protects fragile items from scratches and breakage. In the cited example, laminated kraft and bubble wrap construction provides stiffness and puncture resistance while remaining lightweight.
• Water‑resistant: The laminated outer layer helps protect against moisture during transit.
• Self‑seal and tamper‑evident: Like poly mailers, bubble mailers usually have a peel‑and‑seal flap for fast packing.
• Multiple sizes: Bubble mailers come in standard sizes (e.g., A/000, C/0, C/1, etc.) that correspond to internal dimensions. For example, a C/0 padded envelope has internal dimensions around 165 mm × 165 mm and can accommodate a single DVD case, while a C/1 envelope (around 180 mm × 235 mm) fits thicker box sets.
• Protective but heavier: The cushioning layer makes bubble mailers heavier and bulkier than poly mailers. That additional thickness can push a shipment into a more expensive postal category.

Best products for bubble mailers

Bubble mailers are designed for fragile or breakable items. DVDs, CDs, books, jewellery, small electronics, cosmetics and accessories benefit from the cushioning provided by bubble wrap. The previously cited DVD mailer product states that the inside of the mailer can hold one standard DVD or up to two slim DVD boxes, and the laminated bubble‑wrap construction reduces shipping weight while ensuring the contents remain safe.

Poly mailers vs bubble mailers – side‑by‑side comparison

Summary

Poly mailers prioritise low weight and postage savings, while bubble mailers prioritise cushioning and protection. If you sell clothing or textiles, poly mailers will likely save you money. If you ship DVDs, jewellery or delicate electronics, bubble mailers provide the padding needed to prevent damage. Many online retailers stock both mailer types so they can choose the appropriate option for each product.

Cost & shipping considerations

Postage in the UK is based on both weight and size. Royal Mail’s Large Letter category accepts items up to 165 mm × 240 mm and under 100 g. Anything thicker than 25 mm or heavier than 750 g is classed as a Small Parcel, which has a higher postage rate. Because poly mailers are thin and lightweight, they often keep shipments within the Large Letter band or the lower end of Small Parcel pricing. For example, sending a DVD in a slim poly mailer may fit into the Large Letter category, whereas the same disc in a bubble mailer could exceed the 25 mm thickness and be charged as a Small Parcel.

Bubble mailers also cost more to purchase than plain poly bags. However, they offer extra protection, which can reduce the risk of returns or refunds due to damage. Laminated kraft and bubble wrap construction provides stiffness and puncture resistance while remaining lightweight, so bubble mailers still cost less to ship than boxes. The key is to balance the value of the items you’re shipping with the additional postage and packaging cost.

Eco‑friendly options

More consumers now expect sustainable packaging, and both poly and bubble mailers offer green alternatives:

• Recycled poly mailers – These are made from post‑consumer recycled polyethylene. They have the same strength and waterproof properties as virgin plastic mailers but use less virgin material. Some are coloured grey to avoid the use of dyes.
• Compostable poly mailers – Bioplastic mailers made from cornstarch, PLA or PBAT can break down in industrial composting. They are ideal for eco‑conscious brands but cost more than standard mailers.
• Recyclable padded paper mailers – For customers who want plastic‑free packaging, padded paper envelopes use recycled paper fibres to create a cushioned interior. They are kerbside recyclable in most councils.
• Reusable mailers – Re‑useable mailers with second adhesive strips let customers send items back without needing a new bag. This reduces waste and appeals to fashion rental businesses or returns‑heavy retailers.

EPackaging Direct offers a range of sustainable options, including recycled grey poly mailers, compostable mailers made from plant‑based materials and recyclable padded paper mailers. By choosing the right eco option you can align your brand with customers’ environmental values without sacrificing performance.

Which should you choose? A decision framework

Ultimately the right choice depends on your product and priorities:

• Choose poly mailers if… your items are non‑fragile, such as clothing, textiles, soft toys or accessories. You want the cheapest shipping and to stay within Royal Mail’s Large Letter or light Small Parcel categories. You also want to reduce storage space and packaging costs.
• Choose bubble mailers if… you’re sending breakable or delicate goods like DVDs, CDs, jewellery, small electronics, handmade crafts or cosmetics. The cushioning provided by the bubble wrap lining reduces the risk of damage and customer complaints.
• Still unsure? Many businesses stock both options and decide based on the product. This approach ensures you always use the right level of protection without overpaying for shipping.

Frequently asked questions

Are poly mailers cheaper to ship than bubble mailers?
Yes. Poly mailers are extremely lightweight, so they reduce both the actual weight and the dimensional weight of a parcel. By comparison bubble mailers are heavier and thicker because of the bubble wrap lining. This can push a parcel into a more expensive Royal Mail Small Parcel category.

Do bubble mailers protect items better than poly mailers?
Bubble mailers provide cushioned protection thanks to the air‑filled bubbles. A cited product page notes that a 3/16‑inch bubble layer provides shock absorption and puncture resistance. Poly mailers do not have built‑in cushioning; they only protect against moisture and tearing, so they are suited to items that won’t break.

Can I use poly mailers for Royal Mail Large Letter?
Often yes. A Large Letter must be under 165 mm × 240 mm and less than 25 mm thick and weigh under 100 g. Many clothing items or flat goods in poly mailers meet these dimensions. Bubble mailers sometimes exceed the thickness limit.

Are bubble mailers recyclable in the UK?
Paper‑padded mailers are widely recyclable with paper. Poly bubble mailers (plastic outer with bubble lining) may require separation of materials, so check local recycling guidelines. Some councils accept them with plastic bags and film recycling.

What products should not be shipped in poly mailers?
Avoid sending fragile items that could break, scratch or leak in transit. DVDs, glassware, jewellery, cosmetics, or electronics should be packed in bubble mailers or boxes with additional padding.

Are compostable poly mailers strong enough?
Compostable mailers made from cornstarch or PLA are durable and tear‑resistant but may not be as puncture‑proof as conventional polyethylene. They are suitable for clothing and soft goods; for heavy or sharp items, use recyclable poly mailers or paper padded mailers.

Do bubble mailers count as parcels with Royal Mail?
If the bubble mailer’s thickness pushes it over 25 mm or its weight exceeds 100 g, Royal Mail classifies it as a Small Parcel. Many bubble mailers fall into this category, but small sizes (C/0) with a slim item may still qualify as a Large Letter.

Can I brand poly or bubble mailers with logos?
Yes. Poly mailers can be printed in custom colours or with your logo. Bubble mailers can be customised on the exterior (kraft or plastic). Branding turns your packaging into a marketing channel and enhances your unboxing experience.

Which is better for clothing – poly or bubble mailers?
For most clothing, poly mailers are the best choice. They are lightweight, flexible and protect against moisture. Use a bubble mailer only for delicate garments with embellishments that could be crushed or scratched.

Can I order poly and bubble mailers in bulk with discounts?
With ePackaging Direct you can order any quantity you need. We offer no minimum order value, mix‑and‑match bulk discounts up to 86% and next‑day UK delivery. This allows SMEs and large warehouses alike to stock packaging cost‑effectively.

Conclusion

Selecting the right mailer is vital for keeping shipping costs down, protecting your products and delivering a professional brand experience. Poly mailers are ultra‑lightweight, moisture‑resistant and perfect for clothing and other soft goods, helping you stay within lower Royal Mail postage bands. Bubble mailers add cushioning to protect fragile items like DVDs, jewellery and electronics; their laminated construction provides stiffness and puncture resistance. However they are bulkier and may trigger higher postage.

No single solution fits every product. Many businesses keep both poly and bubble mailers on hand so they can choose the right packaging for each order. When you source from ePackaging Direct, you benefit from no minimum order value, bulk discounts, next‑day delivery and a range of eco‑friendly options. Choose the mailer that matches your product’s needs – and let us handle the rest.