window.uetq = window.uetq || []; window.uetq.push(‘event’, ‘submit_lead_form’,{ event_label:‘SUBMIT MESSAGE’ }); window.lintrk('track', { conversion_id: 10271009 }); window.lintrk('track', { conversion_id: 10271017 });

Corrugated vs Poly Mailers: Choosing the Right Ecommerce Packaging

Corrugated vs Poly Mailers: Choosing the Right Ecommerce Packaging

In the world of ecommerce, packaging plays a crucial role in ensuring that products reach customers in perfect condition while also reflecting the brand’s image and values. Among the various packaging options available, corrugated and poly mailers are two popular choices. Each option has its own set of advantages and considerations, making the decision between them an important one for any ecommerce business. In this blog post, we’ll delve into the details of corrugated and poly mailers to help you make an informed choice for your ecommerce packaging needs.

Corrugated Mailers


  1. Protection and Durability: Corrugated mailers, often made from sturdy corrugated cardboard, offer exceptional protection to fragile items. The multi-layered structure of corrugated material provides cushioning and absorbs shocks during transit, minimizing the risk of damage.
  2. Customization: Corrugated mailers can be easily customized to fit your brand’s identity. They can be printed with high-quality graphics, logos, and branding elements, enhancing your brand recognition and creating a memorable unboxing experience for customers.
  3. Versatility: These mailers come in various sizes and shapes, making them suitable for a wide range of products. Additionally, they can be used for products of different weights without compromising on protection.
  4. Eco-Friendly Options: Many consumers appreciate sustainable packaging choices. Corrugated mailers can be sourced from recycled materials and are biodegradable, aligning with environmentally conscious values.


  1. Weight and Shipping Costs: Corrugated mailers are heavier than poly mailers, which can result in higher shipping costs, especially for businesses shipping products in bulk or internationally.
  2. Storage Space: Due to their rigid structure, corrugated mailers might require more storage space compared to flat-folded poly mailers.
Mailer Subscription Box
Mailer Subscription Box

Poly Mailers


  1. Lightweight: Poly mailers are made from thin, lightweight plastic materials, which can help reduce shipping costs, particularly for businesses that ship large quantities.
  2. Water-Resistant: Poly mailers provide a level of water resistance, protecting products from minor exposure to moisture during transit. This feature is particularly useful for products that are not inherently waterproof.
  3. Flexibility: Poly mailers are flexible and take up less storage space compared to corrugated mailers. They can be stored flat and easily folded when needed.
  4. Tear-Resistant: These mailers are designed to resist tears and punctures, providing an extra layer of protection against potential damage.


  1. Limited Cushioning: While poly mailers offer some level of protection, they may not be suitable for very delicate or fragile items without additional cushioning.
  2. Branding Limitations: While poly mailers can be printed on, the printing quality might not be as high as what’s achievable on corrugated mailers.
  3. Environmental Impact: Poly mailers are often made from plastic materials that are not biodegradable. This can be a concern for environmentally conscious customers.
Poly Mailer
Poly Mailer With Logo
Poly Mailers With Labels

Choosing the Right Option

Ultimately, the choice between corrugated and poly mailers depends on the nature of your products, your brand image, and your budget considerations. If your priority is to provide maximum protection for fragile items and to create a strong branding impression, corrugated mailers might be the way to go. On the other hand, if cost efficiency, lightweight packaging, and flexibility are more important for your business, poly mailers could be the better choice.

Remember, you can also explore hybrid options. For instance, some businesses use corrugated mailers for fragile items and poly mailers for less delicate products, striking a balance between protection and cost-effectiveness.

In the end, the ideal packaging solution considers both the practical aspects of safe product transit and the emotional aspects of customer experience. Whichever option you choose, make sure it aligns with your brand’s values and meets your customers’ expectations.

If you are interested in ecommerce packaging solutions, then partner with Brown Packaging today to get started.

Most Recent Posts:
Subscribe To Our Newsletter

By submitting your information, you agree to our terms and conditions and privacy policy.

Mailer Subscription Box
Ecommerce Packaging
Relevant Posts