Paper Padded Mailers Made to Your Size and Print
A paper padded mailer is a flat envelope with a cushioned paper lining and a self-seal flap. It suits slim items up to about 20 mm thick, such as jewellery, books, prints, phone cases and small accessories.
From £0.25 a box exact price on a written quote, within one working day
- Free design proof before anything is printed
- Production takes 4 to 6 working days after proof approval
- Free tracked UK mainland delivery in 2 to 3 working days
- Misprints or damage reported within 10 days with photos are reprinted or refunded
- Low minimums, quoted per job
Specification
What paper padded mailers from us are made of and how they are measured. Anything not listed here, ask in the quote.
| Style | Flat envelope with a cushioned paper lining and fold-over flap |
|---|---|
| Padding | Honeycomb or ribbed paper layer between outer and inner sheets |
| Size range | 150 x 100 mm to 450 x 330 mm, length x width |
| Typical start | 250 x 180 mm, adjusted to your item |
| Contents | Items up to about 20 mm thick |
| Closure | Peel-and-seal adhesive strip on the flap |
| Plain, one colour, two colours or full colour on the outside | |
| Supplied | Flat, packed in counted bundles |
| Price | From £0.25 a box; exact price depends on size, board, print and quantity |
How to measure for a paper padded mailer
Measure the item, wrapped as it will be posted, across its length, width and thickest point. Add about 20 mm to the length and the width, more if the item is thick, because the padding takes up room as it bends around the contents.
Send us the length x width you want and the thickness of the item. If it is more than about 20 mm thick, a slim mailer box will treat it better.
Which padded mailer for which job
A honeycomb paper lining gives a softer, springier cushion that suits jewellery, cosmetics and small hard items. A ribbed lining lies flatter and suits books, prints and cards that mainly need their corners kept sharp.
Design Your Paper Padded Mailer
Drop your logo on a real photo of our paper padded mailers, set the size and quantity, and send it. A designer sets up the real dieline and sends a free proof.
Your logo is placed on a real photo of our box. A designer redraws it to scale on the dieline and sends a free proof before anything is printed.
What is a paper padded mailer?
It is an envelope built from layers of paper. An outer sheet takes the address and your print, a padding layer sits in the middle, and an inner sheet faces the contents. A flap with a peel-off strip closes the open end.
Because it is flat until filled, it posts slim items without the bulk of a box. It belongs to our mailers and padded mailers range, which covers the soft and envelope styles we make.
What fits in a paper padded mailer?
Anything flat enough to lie under 20 mm or so, and firm enough not to crush under a light knock. The padding stops sharp edges poking through and softens a drop on a sorting belt.
- Rings, earrings and necklaces in a small pouch or card.
- Paperback books, notebooks and diaries.
- Art prints and greeting cards backed with a stiff sheet.
- Phone cases, watch straps and other small accessories.
- Make-up palettes, lip products and slim skincare tubes.
- Socks, ties, scarves and folded silk items.
If an item rattles inside the envelope, wrap it in a sheet of tissue first so it stays in the centre of the padding.
How does the paper lining cushion the contents?
The middle layer is shaped paper rather than a flat sheet. In a honeycomb lining, rows of small paper cells squash and spring back when the envelope is pressed. In a ribbed lining, long paper ridges run along the mailer and spread a knock along their length.
Neither lining turns the mailer into a box. It protects against scuffs, dents and a corner catching, but a glass item or something that snaps under a bend still needs rigid walls.
What size paper padded mailer do I need?
Size the envelope by its length x width. Allow room for the thickness of the item, because a 15 mm book uses about 15 mm of each side as the envelope wraps over it.
| Item | Mailer to try | Band to check |
|---|---|---|
| Ring or earrings in a gift card | 150 x 100 mm | Large Letter |
| A5 notebook | 250 x 180 mm | Large Letter |
| A4 print on a backing board | 330 x 240 mm | Large Letter |
| Paperback novel | 240 x 170 mm | Large Letter |
| Phone case in its sleeve | 200 x 130 mm | Large Letter |
| Two folded scarves | 350 x 250 mm | Large Letter or Small Parcel |
These are starting points; your packed item decides the final figure. Our guide to sizes and Royal Mail postal bands explains how each band is measured.
Will a padded mailer go as a Large Letter?
Often, yes. Royal Mail Large Letter allows 353 x 250 x 25 mm, so a filled padded mailer has to stay under 25 mm at its thickest point. Padding adds a few millimetres to each face, which is why we suggest contents of about 20 mm or less.
Measure a filled sample with a ruler before you plan postage around it. Check the current band limits before you order, because a mailer that misses Large Letter by a couple of millimetres costs more at every send.
How do you pack and seal a padded mailer?
Packing takes seconds, and a little care at the flap keeps the seal flat and the front neat for the label.
- Slide the item in so its longest side runs along the length of the mailer.
- Push it to the closed end so the flap has a clean edge to fold over.
- Peel the backing strip off the adhesive in one steady pull.
- Fold the flap down and press from the middle outwards to stop wrinkles.
- Stick the address label on the flat front, clear of the flap.
Can paper padded mailers be printed?
Yes. The outer sheet takes plain, one colour, two colour or full colour print on the front, the back or both. Kraft outers suit a single dark logo; coloured outers suit a bold pattern with a white logo on top.
Leave a clear panel for the address label and keep text away from the flap fold, where it can crack. The free proof shows exactly where each element lands on the flat envelope before printing starts. The printed finishes range for mailers shows the print options side by side.
Padded mailer or slim mailer box?
Choose the padded mailer when the item is flat, light and posted often, and when Large Letter postage matters. It packs faster and takes less shelf space.
Move to a box when the item is thicker than about 20 mm, needs to stand upright, or would be ruined by a bend. A small corrugated box is the safer home for candles, ceramics and glass. Our folding small mailing boxes are the next step up.
How do padded mailers arrive?
They come flat, packed in counted bundles, with free tracked UK mainland delivery in 2 to 3 working days. A carton of padded mailers stands on a shelf beside your packing area and you pull one at a time.
Keep them somewhere dry and away from radiators, ideally in the carton they came in. Heat can soften the adhesive strip, and damp air can make the paper cockle.
Which padded mailer mistakes should you avoid?
- Ordering the exact item size, so the flap will not reach the seal line.
- Posting a 30 mm item and then paying parcel rates on every send.
- Putting the address label over the flap, where it tears when opened.
- Printing a pale colour across a kraft outer and expecting it to stay bright.
- Using a padded mailer for glass that would be safer in a box.
How to order paper padded mailers
Tell us the length x width, the item thickness, the quantity and your print idea. We send a written quote within one working day, from £0.25 a mailer, with low minimums quoted per job.
You get a free proof first and nothing is printed until you approve it. Production takes 4 to 6 working days after approval. If a misprint or damage turns up, send photos within 10 days for a reprint or refund. Ask for a written quote for padded mailers or email info@themailerboxes.co.uk.
Related mailer boxes
Other closures and finishes that start from the same idea.
Compostable MailersSoft mailer for clothing and textiles, printed to orderFrom £0.25 a box
Folding Small Mailing BoxesFlat-packed, folds up in seconds, from 100 mmFrom £0.25 a box
Literature MailersShallow and rigid for brochures, prints and samplesFrom £0.25 a box
Brown Kraft Mailer BoxesPlain kraft, one or two colour print if you want itFrom £0.25 a boxPaper Padded Mailers questions
How thick can the item be in a paper padded mailer?
About 20 mm works well. Thicker items stretch the envelope and can push it out of the Large Letter band.
Does a paper padded mailer use bubble film inside?
Our paper padded mailers use a shaped paper layer, either honeycomb cells or ribs, as the cushion. Tell us if you have seen a particular lining you prefer.
Can a paper padded mailer be printed on both sides?
Yes. Front and back can both carry print, in one colour, two colours or full colour.
What closure does a paper padded mailer have?
A fold-over flap with a peel-and-seal adhesive strip. Peel the backing, fold and press, and no tape is needed.
Will jewellery be safe in a paper padded mailer?
Small pieces in a pouch or on a card travel well, because the padding stops edges poking through. Fragile glass beads are better in a small box.
Can I get paper padded mailers in a colour other than kraft?
Yes. Coloured outers are available, and full colour print can cover the whole outer sheet. The proof shows the colour before anything is printed.
Is a paper padded mailer stiff enough for art prints?
Add a backing board behind the print. The padding guards the corners, and the board stops the print bending in the post.
What is the smallest paper padded mailer you make?
About 150 x 100 mm. That suits a ring box, earrings on a card or a small accessory.
Can paper padded mailers hold books?
Yes. A paperback or notebook is one of the best fits, and a ribbed lining keeps the cover corners sharp.
Where should the address go on a paper padded mailer?
On the flat front, away from the flap. We can print a clear panel there so the label always lands in the same place.
Can the inside of a paper padded mailer be printed?
The inner sheet sits against the padding, so printing it is not practical. Put your message on a printed card inside instead.
What if paper padded mailers arrive damaged?
Send photos within 10 days and we reprint or refund. The returns and reprints page sets out the steps.
Your question is not here? Ask on WhatsApp or call +44 7578 382054.
Tell us what you post
Send the product, a rough inside size and a quantity. We reply in writing within one working day with a price and a free design proof. Prefer to talk? Call +44 7578 382054 or message us on WhatsApp.