Custom Mailers
Custom Mailers
Looking for high-quality custom mailers to elevate your brand’s packaging? PAC by ProAmpac specializes in designing and producing custom bubble, flat poly, and paperboard mailers, including our innovative Ecojacket® recyclable mailers. With full design support from layout to mock-ups, our team ensures your packaging stands out while providing superior protection. Whether you need vibrant, edge-to-edge printing with our advanced flexographic capabilities or a sleek, minimalist design, we tailor every mailer to fit your brand’s unique needs. Our custom mailers are built to enhance your brand’s visibility while ensuring your products arrive safely.
Trusted by businesses of all sizes, PAC delivers durable, high-quality mailers that make an impact from the moment they arrive. Our custom solutions help you reinforce your brand with every shipment, ensuring a premium unboxing experience. With minimum order quantities of 25,000 mailers, we cater to growing brands looking for professional, custom-branded packaging. Explore our diverse custom mailers, from poly bubble mailers to eco-friendly kraft mailers, and bring your packaging vision to life today!
PAPER MAILERS
Ecojacket®: Fully Curbside Recyclable Mailer
Our patent-pending Ecojacket® recyclable mailers are eco-friendly, conformable, lightweight, and built with protective kraft-padded paper. The exterior paper is bonded to a fluted interior paper for effective cushioning protection and is constructed with a bottom fold and strong side seals for superior bursting strength.
Ecojacket® Max
The Ecojacket® Max is a durable, gusseted paper mailer designed for increased fill capacity and efficiency. Fully curbside recyclable and made from heavyweight paper, it’s ideal for shipping clothing, linens, and accessories. With custom branding options and easy-open tear strips, it’s a sustainable, high-quality packaging solution.
Airjacket®: Lightweight Poly Bubble Mailers
Ideal for items needing extra protection, Airjacket® poly bubble mailers offer durable, moisture-resistant packaging with a professional look. Featuring a self-sealing closure, PACzip tear strip, and tough side seals, they’re available with 50% recycled content and customizable branding for a sustainable solution.
Jumbojacket®: Ultra Thick ½” Poly Bubble Mailers
Jumbojacket® large bubble mailers offer durable, lightweight protection for fragile items like books and electronics. Made from recyclable #2 HDPE, they reduce DIM weight costs and the need for bulky packaging while allowing for custom branding.
Kraft Airjacket®: Kraft Paper Bubble Mailers
Kraft Airjacket® is a lightweight, protective bubble mailer with a durable kraft paper exterior laminated to a resilient bubble interior for superior cushioning. Ideal for shipping fragile items, it offers burst-resistant protection with a professional appearance while reducing the need for bulky boxes and void fill. Custom printing is available to help your brand stand out on every shipment.
CoolPAC®: Thermal Mailers
CoolPAC® is a thermal bubble packaging solution designed to keep temperature-sensitive items protected in transit. Made with a specialized bubble that reduces heat and cold transfer, CoolPAC® mailers, box liners, and roll stock are constructed from FDA-approved materials and are fully recyclable through the NextTrex and How2Recycle programs. Perfect for meal kits, chocolates, pharmaceuticals, and more, CoolPAC® combines reliable thermal protection with a more sustainable footprint.
Polyjacket®: Flat Poly Mailers
Polyjacket® is a lightweight, moisture-resistant flat mailer designed for e-commerce, fulfillment, and distribution. Made from durable, multi-layer polyethylene film with up to 100% recycled content, it resists tears and punctures while reducing shipping costs. Ideal for apparel and soft goods, Polyjacket® offers custom printing up to 10 colors for strong brand impact with sustainable performance.
Gusseted Polyjacket®
Gusseted Polyjacket® is a lightweight, moisture-resistant mailer designed to handle bulkier items with ease. Made from durable, multi-layer polyethylene film with up to 100% recycled content, it offers tear and puncture resistance while reducing shipping costs. The expandable gusset provides extra capacity, and custom printing up to 10 colors delivers strong brand impact with sustainable performance.
WicketPAC®: Flat poly mailers that fit wicket stands
PAC Worldwide’s WicketPAC® is a durable, moisture-resistant flat poly mailer designed for high-speed, efficient packing. Made with up to 48% recycled content, it offers tear and puncture resistance while reducing packaging waste and shipping costs. Mounted on wickets for quick loading, WicketPAC® boosts throughput by up to 20%, and custom printing up to 10 colors puts your brand front and center with every shipment.
Mailjacket®: Rigid Paperboard Mailers
PAC Worldwide’s Mailjacket® is a rigid, all-paper mailer that protects your “do-not-bend” items with durable, 100% recyclable construction. Made from up to 100% recycled paper, it delivers professional, tamper-evident protection for documents, books, photos, and more. With a quick-release self-adhesive closure and optional custom printing, Mailjacket® ensures your shipments arrive secure, undamaged, and on brand.
Frequently Asked Questions - Custom Mailers
What types of mailers can be customized?
PAC offers tailor-made solutions across formats—including bubble, flat poly, and paperboard mailers, as well as recyclable Ecojacket® options—ensuring versatility for your brand’s needs.
What printing options are available for custom mailers?
Custom mailers can feature anything from basic black text to full edge‑to‑edge flexographic prints in up to 10 colors, including complex designs and varnishes.
What design support does PAC provide for custom mailers?
PAC’s comprehensive design support covers everything from layout and mock‑ups to virtual samples, artwork placement, and one‑on‑one design consultations—guiding you from concept to completed packaging.
Is there a minimum quantity for custom-branded mailer orders?
Yes. Standard custom mailer orders start at a minimum of 25,000 units per size. For custom sizes or smaller quantities, stock or label-based solutions may be more practical.
How does PAC support sustainability in custom mailers?
PAC’s design services include eco-conscious choices—from recyclable substrates like Ecojacket®, to using recycled content and selecting mailers approved under How2Recycle and other recycling programs.
