Boxes vs Mailers: What to Choose for Shipping

Both businesses and individuals who use postal services are looking for ways to reduce shipping costs without sacrificing the security of the items they ship. One key factor that can affect shipping costs is the choice between poly mailers (envelopes) and shipping boxes. To make this choice, you need to understand the pros and cons of each option.

A poly mailer is a type of lightweight, durable shipping bag made from a blend of plastic materials, typically polyethylene; it usually has a self-sealing strip and may or may not have bubble cushioning inside. Mailers are known for being flexible, waterproof, tear-resistant, and inexpensive, making them a popular choice for those looking to reduce shipping costs. Shipping boxes are lightweight but durable boxes, typically made of corrugated cardboard. Both mailers and boxes come in a variety of sizes to accommodate different types of items.

Poly mailers are less expensive to purchase than boxes (unless we’re talking about free flat-rate shipping supplies, in which case the point is moot), compact, and lightweight, which is their main advantage because of reduced shipping costs. Padded mailers also provide some protection for the items inside, as long as they are not fragile. The main downsides of mailers are their limited capacity, which makes them unsuitable for large or bulky items, and inadequate protection for fragile items.

Boxes are a much more versatile option than mailers because they can be used to safely ship items of varying weights and sizes, and usually provide adequate protection even for valuable or fragile items (as long as you remember to fill any empty space inside the box with some type of filler). On the other hand, boxes are heavier and more expensive than mailers, which can increase your shipping costs.

So, neither bubble mailer nor box is the perfect option, and your choice will ultimately depend on the items you’re shipping. Bubble envelopes are considered the more convenient and less expensive option for small or medium-sized, lightweight, and non-fragile items, such as clothing, accessories, books, and other flat/compact and non-breakable items, while corrugated shipping boxes, which provide additional protection, are used for larger, heavier, fragile, or high-value items.

E-commerce businesses must also consider the customer experience when choosing between mailer bags and boxes. While boxes may increase shipping costs, which will cut into your profits if you offer free shipping, they are more customizable than mailers, offer more branding opportunities due to the larger surface area, and can provide an unboxing experience that your customers can share on social media.

On the other hand, mailers take up less storage space and take less time to handle and pack than boxes, which is an important factor to consider if you have large shipping volumes. Again, the choice depends on your individual circumstances and priorities.

One thing you should never do is compromise the safety of the items you’re shipping in order to reduce shipping costs. If you are unsure whether a bubble mailer will provide adequate protection, opt for a box. It’s still possible to reduce your shipping costs when shipping in a box by choosing the right box size and lightweight padding, as well as arranging the items in the box so they take up less space.

The bottom line is that there’s no one-size-fits-all solution: both bubble mailers and boxes have their own pros and cons when it comes to shipping, but your first priority should always be the safety of the items you’re shipping.