Custom Printed Paper Mailers
Sustainable, plastic-free paper mailers with full-colour digital or flexographic printing. The modern replacement for poly mailers.
Poly mailers are out. Time to upgrade.
Digital & Flexo Options
Plastic free doesn't mean plain
FSC-Certified Kraft Paper
100% plastic-free construction, curbside recyclable, and built to meet the standards your customers expect.
Digital or Flexo Print
Digital from 500 units for full-colour, multi-variant runs. Flexo from 5,000 for cost-efficient spot colour at volume.
Honeycomb Lining
Paper-based cushioning built into the mailer wall — impact protection without a single gram of plastic bubble wrap.
Dual Adhesive Seal Strip
One strip to seal, one strip for returns. Clean open, clean close — no scissors, no tape, no faff.
10+ Standard Sizes
From 200×280mm up to 400×500mm. Custom sizing available if you need to cut void space.
500 Unit Digital MOQ
Low enough for a launch run or a limited edition drop — no plate costs, no minimum colour commitments.
Built to your exact requirements
Every custom printed paper mailers is engineered from scratch for your product, brand identity, and customer experience.
Technical Specifications
Common questions about custom printed paper mailers
Everything you need to know before ordering custom custom printed paper mailers.
Should I choose digital or flexo printed paper mailers?
Digital printing is best for orders under 5,000 units, when you need full-colour photographic graphics, or when you want to run multiple design variants without plate costs. Flexo printing is more cost-effective at volumes above 5,000 and works well for clean logo-based designs in 1–3 spot colours. We'll always recommend the best option based on your volumes and design requirements.
Are paper mailers strong enough to replace poly mailers?
Yes — modern paper mailers are designed specifically to replace poly. Honeycomb-lined options provide excellent cushioning and impact protection. For lightweight items like clothing, accessories, and beauty products, standard paper mailers are more than sufficient. For heavier or more fragile items, we'd recommend padded variants or testing with a sample order first.
What sizes are available?
We stock over 10 standard sizes ranging from small (200x280mm) to large (400x500mm). Custom sizing is also available — we'll help you find the optimal size to reduce void space and minimise shipping costs while still protecting your product properly.
Can paper mailers have a returns seal strip?
Yes. Our paper mailers come with dual adhesive strips as standard — one for initial sealing and a second strip for easy returns. This is a must-have for ecommerce brands looking to improve the customer experience and simplify their returns process.
How much do custom paper mailers cost?
Digital printed paper mailers start from approximately 40–80p per unit at 500 quantity depending on size. Flexo printed mailers start from around 15–35p per unit at 10,000+. Padded/honeycomb options are slightly more. We provide full pricing breakdowns including any plate charges for flexo.
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Custom Printed Rigid Boxes
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Packaging insights & guides
Built To Order: When Does Custom Packaging Make Sense?
As your brand grows you’ll be faced with a decision on how custom you go with packaging. We’ll talk you through it.
Setup For Success: Tooling Costs In Packaging
Our guide to setup costs in custom packaging: why they are necessary, cost ranges and alternatives.
Sticker Shock: Why Are Your Packaging Costs Going Up?
We'll break down why packaging costs are rising and what you can do about it
Ready to create premium custom printed paper mailers?
Tell us about your project. We'll come back with a transparent quote, timeline, and sample plan within 48 hours.