How to Print on Poly Mailers: A Comprehensive Guide to Customizing Your Packaging

How to Print on Poly Mailers: A Comprehensive Guide to Customizing Your Packaging

Poly mailers have become a popular choice for businesses and individuals looking for a lightweight, durable, and cost-effective packaging solution. Whether you’re shipping clothing, accessories, or other lightweight items, poly mailers offer a sleek and professional appearance. However, to truly stand out, many businesses opt to print custom designs, logos, or branding on their poly mailers. In this article, we’ll explore the various methods, considerations, and tips for printing on poly mailers, ensuring your packaging not only protects your items but also leaves a lasting impression.

1. Understanding Poly Mailers: The Basics

Before diving into the printing process, it’s essential to understand what poly mailers are made of. Poly mailers are typically constructed from polyethylene, a type of plastic that is both flexible and resistant to tearing. This material is ideal for shipping lightweight items, as it provides a protective barrier against moisture, dirt, and minor impacts. However, the smooth, non-porous surface of poly mailers can present challenges when it comes to printing, as not all inks adhere well to this type of material.

2. Choosing the Right Printing Method

When it comes to printing on poly mailers, there are several methods to consider, each with its own advantages and limitations:

a. Flexographic Printing

Flexographic printing is a popular choice for large-scale production runs. This method uses flexible relief plates and fast-drying inks, making it suitable for printing on a variety of materials, including poly mailers. Flexographic printing is cost-effective for high-volume orders and can produce vibrant, high-quality designs. However, it may not be the best option for small businesses or those with limited budgets, as the setup costs can be high.

b. Digital Printing

Digital printing is a more flexible option, especially for smaller businesses or those looking to print custom designs in smaller quantities. This method uses digital files to print directly onto the poly mailer, allowing for greater customization and faster turnaround times. Digital printing is ideal for intricate designs, gradients, and full-color images. However, it may not be as durable as other methods, and the cost per unit can be higher for large orders.

c. Screen Printing

Screen printing is another option, particularly for businesses looking to print simple, bold designs or logos. This method involves pushing ink through a mesh screen onto the poly mailer, creating a durable and long-lasting print. Screen printing is cost-effective for medium to large orders and works well with solid colors. However, it may not be suitable for highly detailed or multi-colored designs.

d. Heat Transfer Printing

Heat transfer printing involves using heat to transfer a design from a special paper or film onto the poly mailer. This method is ideal for small batches or custom orders, as it allows for precise placement of the design. Heat transfer printing can produce vibrant, high-quality prints, but it may not be as durable as other methods, especially if the mailer is subjected to rough handling during shipping.

3. Design Considerations for Poly Mailer Printing

When designing your poly mailer, there are several factors to keep in mind to ensure the best possible results:

a. Color Selection

Poly mailers are typically available in a range of colors, including white, black, and various pastel shades. When choosing colors for your design, consider how they will contrast with the base color of the mailer. Bright, bold colors tend to stand out more, while softer tones can create a more subtle, elegant look.

b. Logo and Branding

Your logo is a crucial element of your branding, and it should be prominently displayed on your poly mailer. Ensure that your logo is high-resolution and scalable, so it looks sharp and clear regardless of the size of the mailer. Consider placing your logo on both the front and back of the mailer for maximum visibility.

c. Typography

The font you choose for any text on your poly mailer should be easy to read and align with your brand’s aesthetic. Avoid using too many different fonts, as this can make the design look cluttered. Instead, opt for a clean, consistent typography style that complements your logo and overall design.

d. Graphics and Images

If you’re including graphics or images on your poly mailer, make sure they are high-quality and relevant to your brand. Avoid using overly complex designs that may not translate well to the printing process. Simple, bold graphics tend to work best on poly mailers.

4. Preparing Your Artwork for Printing

Once you’ve finalized your design, it’s time to prepare your artwork for printing. Here are some tips to ensure a smooth printing process:

a. File Format

Most printing companies prefer vector files (such as .AI or .EPS) for logos and graphics, as they can be scaled without losing quality. For images, high-resolution JPEG or PNG files are typically acceptable. Be sure to check with your printer for their specific file requirements.

b. Bleed and Margins

When designing your poly mailer, include a bleed area (usually around 0.125 inches) to ensure that your design extends to the edges of the mailer without any white borders. Additionally, keep important elements (such as text and logos) within the safe margin to avoid them being cut off during the trimming process.

c. Proofing

Before sending your design to print, request a proof from your printing company. This will allow you to review the design and make any necessary adjustments before the final print run. Pay close attention to colors, alignment, and overall quality to ensure your poly mailers look exactly as you envisioned.

5. Environmental Considerations

As more businesses and consumers become environmentally conscious, it’s important to consider the sustainability of your packaging choices. Poly mailers are generally recyclable, but not all recycling facilities accept them. To minimize your environmental impact, consider using eco-friendly poly mailers made from recycled materials or those that are biodegradable. Additionally, you can encourage your customers to recycle their mailers by including a message on the packaging.

6. Cost Considerations

The cost of printing on poly mailers can vary depending on the printing method, quantity, and complexity of the design. Here are some factors to consider when budgeting for your poly mailer printing:

a. Quantity

The more poly mailers you order, the lower the cost per unit. If you have a high-volume business, it may be worth investing in a larger print run to save money in the long run.

b. Printing Method

As mentioned earlier, different printing methods come with different costs. Flexographic printing is typically the most cost-effective for large orders, while digital printing may be more affordable for smaller quantities.

c. Design Complexity

The more complex your design, the higher the printing costs may be. Intricate designs with multiple colors or gradients may require more advanced printing techniques, which can increase the overall cost.

7. Tips for Successful Poly Mailer Printing

To ensure your poly mailers look professional and meet your expectations, keep the following tips in mind:

a. Work with a Reputable Printer

Choose a printing company with experience in printing on poly mailers. Look for reviews, ask for samples, and ensure they have the necessary equipment and expertise to handle your project.

b. Test Your Design

Before committing to a large print run, consider ordering a small batch of poly mailers to test your design. This will allow you to make any necessary adjustments and ensure the final product meets your standards.

c. Consider the End User

Think about how your customers will interact with your poly mailers. Is the design eye-catching and memorable? Does it reflect your brand’s values and personality? Keep the end user in mind when designing your mailers to create a positive and lasting impression.

8. Conclusion

Printing on poly mailers is a great way to enhance your brand’s visibility and create a professional, cohesive packaging experience for your customers. By understanding the different printing methods, considering design elements, and working with a reputable printer, you can create custom poly mailers that not only protect your items but also leave a lasting impression. Whether you’re a small business owner or part of a larger organization, investing in high-quality printed poly mailers can help you stand out in a competitive market and build brand loyalty.


Q: Can I print on both sides of a poly mailer? A: Yes, you can print on both sides of a poly mailer. However, keep in mind that printing on both sides may increase the overall cost, and you’ll need to ensure that the design on one side doesn’t interfere with the other.

Q: How durable is the print on poly mailers? A: The durability of the print depends on the printing method used. Flexographic and screen printing tend to be more durable, while digital and heat transfer printing may be less resistant to wear and tear. Consider the handling your mailers will undergo during shipping when choosing a printing method.

Q: Can I print custom shapes or cutouts on poly mailers? A: While it’s possible to create custom shapes or cutouts on poly mailers, this typically requires specialized equipment and may increase the cost. If you’re interested in custom shapes, discuss your options with your printing company to determine the feasibility and cost.

Q: Are there any restrictions on the types of designs I can print on poly mailers? A: Most printing companies have guidelines regarding the types of designs they can print, particularly when it comes to color gradients, fine details, and intricate patterns. Be sure to review your printer’s design guidelines and consult with them if you have any questions about your design.

Q: How long does it take to print custom poly mailers? A: The turnaround time for printing custom poly mailers can vary depending on the printing method, quantity, and complexity of the design. Digital printing typically has a faster turnaround time, while flexographic printing may take longer due to the setup process. Be sure to discuss timelines with your printer to ensure your mailers are ready when you need them.