Many businesses struggle to find affordable, high-quality custom packaging solutions that truly represent their brand. This guide, “How to Make Custom Poly Mailers: Design, Print & Order,” helps you know this. We’ll walk you step-by-step through the entire process from initial design concepts to final product delivery. Let’s explore it!

1. Designing your custom poly mailers

1.1 Choosing the right size and material

The initial stage in procuring custom poly mailers involves carefully selecting the appropriate size and material. Standard sizes are widely available and readily accessible, custom dimensions may be an option depending on your chosen supplier’s capabilities. Consulting a size template, if provided by your supplier, can significantly aid in selecting the most appropriate size for your specific needs. 

Beyond size, the material composition of the poly mailer plays a vital role in its performance and suitability. A range of materials are employed in poly mailer production, each possessing distinct advantages and disadvantages that need to be carefully considered in relation to your product’s characteristics and shipping requirements:

• LDPE (Low-Density Polyethylene): A common, lightweight and flexible material, offering good cost-effectiveness but potentially less durability compared to other options.
• HDPE (High-Density Polyethylene): A stronger and more durable material than LDPE, providing better tear and puncture resistance. It is generally more expensive than LDPE.

Environmentally conscious businesses are increasingly adopting biodegradable poly mailers made from plant-based or sustainable materials, offering significant branding advantages despite higher costs. Alternatively, recycled plastic mailers provide a more affordable sustainable solution without compromising product protection.

1.2 Creating your design

Designing your poly mailers involves creating a visually appealing and brand-consistent design. You may consider the following factors:

• Logo Placement: Strategically place your logo for maximum visibility. Consider its size and placement in relation to other design elements.
• Color Schemes: Utilize your brand’s existing color palette to maintain brand consistency and recognition.
• Font Selection: Choose fonts that reflect your brand’s personality and are easy to read.
• Brand Elements: Incorporate other brand elements such as patterns, imagery or taglines to reinforce your brand identity.

1.3 Printing options for poly mailers

Various printing methods are available for poly mailers, each with its own pros and cons, such as:

2. Finding and ordering custom poly mailers

2.1 Working with a printing service

The step-by-step guide assists businesses in navigating the process effectively from initial research to final order fulfillment. Begin your search by researching potential printing services using online search engines. Explore both online printing platforms and traditional printing companies, comparing their portfolios to determine their suitability for your specific project needs. 

Once you’ve identified several potential candidates, you can request quotes from each and provide detailed specifications including desired dimensions, quantity, materials, printing requirements, any special finishing preferences. 

Besides, you can also pay close attention to several critical factors when evaluating these quotes such as cost per unit, total cost, turnaround time, minimum order quantity (MOQ), customer service responsiveness… A thorough comparison of these factors is crucial for making an informed decision that aligns with your budget, timeline and quality expectations. 

2.2 DIY options for small batches

For very small batches or if you need a quick and inexpensive solution, DIY methods might be suitable:

• Stencils: Create stencils of your logo or design and use fabric paint or markers to apply them to the poly mailers. This method is best for simple designs and small quantities.
• Stamps: Custom-made stamps can be used to create repetitive designs or logos on poly mailers. This works well for simple designs but requires a custom stamp.
• Heat Transfer: Heat transfer vinyl (HTV) allows you to create custom designs and apply them using a heat press. This requires a heat press machine and HTV but it allows for more detail than stenciling or stamping.
• Limitations: DIY methods are limited in terms of print quality, color accuracy, and the complexity of designs. They are also generally more time-consuming than professional printing services. For larger quantities or intricate designs, professional printing is highly recommended.

3. Benefits of using custom poly mailers

3.1 Enhancing brand recognition

Custom poly mailers are a powerful tool for enhancing brand recognition and reinforcing your brand identity. Generic packaging fails to leverage the valuable opportunity to build brand awareness during the crucial shipping and delivery phase. Custom-designed mailers, however, transform this overlooked aspect of the customer journey into a memorable branding moment.

3.2 Improving customer experience

Custom poly mailers significantly enhance the customer unboxing experience. This seemingly small detail plays a surprisingly large role in shaping customer perceptions and loyalty.

• Elevated Unboxing: Receiving a well-designed, professional package elevates the unboxing experience, transforming it from a simple delivery into a more engaging and positive interaction.
• Perceived Value: Professional packaging communicates quality and care, enhancing the perceived value of your product. Customers are more likely to associate high-quality packaging with a high-quality product.
• Positive Emotional Impact: A carefully designed package creates a positive emotional response. This can increase customer satisfaction and foster loyalty. The positive feeling associated with a well-presented package can make a significant difference in customer retention. 

4. FAQs about how to make custom poly mailers

4.1 What is the minimum order quantity for custom poly mailers?

Minimum order quantities (MOQs) for custom poly mailers vary significantly depending on the printing service and chosen printing method. Contact potential printing services directly to obtain their specific MOQs.

4.2 What file formats are accepted for printing custom poly mailers?

Commonly accepted file formats for custom poly mailer printing include AI (Adobe Illustrator), PSD (Adobe Photoshop), PDF and SVG (Scalable Vector Graphics). Vector formats (AI, SVG) are generally preferred for their scalability, ensuring high-quality printing regardless of size. Always provide high-resolution images (at least 300 DPI) for optimal print quality.

4.3 Are custom poly mailers eco-friendly?

Whether custom poly mailers are eco-friendly depends entirely on the materials used. For example, for eco-friendly options, many companies now offer custom poly mailers made from recycled materials, biodegradable plastics or even plantable materials. 

For non-eco-friendly options, traditional custom poly mailers are often made from virgin plastics, which are derived from petroleum and contribute to pollution and landfill waste. To ensure you’re getting eco-friendly custom poly mailers, you must specifically ask your supplier about the materials used in their production and inquire about their sustainability certifications or practices.

Read more:

• Are poly mailers recyclable? A complete guide
• Shipping with poly mailers: Guide to sizes, types & benefits
• Best poly mailers for Poshmark: Size, tips and where to buy

Creating custom poly mailers is a powerful investment for businesses of all sizes, transforming ordinary shipping supplies into effective branding tools. This guide has outlined the key steps involved in selecting the right size and material, designing a visually appealing and brand-consistent package. Let’s explore the world of custom packaging and discover how your brand stands out from the competition!