Sustainable custom mailer bags
Make the journey from dispatch to door work harder for your brand. Explore recycled-content, compostable and paper-based mailers, selecting the size, print and protection your shipments need. We’ll help you assess performance and end-of-life claims for the markets you ship to.
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Format directory
Find the right format
Format selection
Choose the right mailer for your brand
What does your mailer need to do?
Start here. The right format depends on how your mailer travels, what's inside it, and what happens after it arrives.
Transit durability: If it's going through a courier network, it needs to handle it. Poly mailers engineered for shipping run at 60–80µm, thick enough to survive handling without tearing or the seal failing. Lighter poly (20–40µm) suits retail or storage, not last-mile shipping.
Closure: A single self-seal strip is standard. If you're running a returns programme, a double strip lets the recipient reseal the mailer and send it back, no extra packaging needed.
Expandable or flat: Flat mailers work well for consistent, low-profile products. If your orders vary in size or depth, an expandable gusseted format gives you the flexibility without going to a box.
Paper or poly: Paper gives you kerbside recyclability and a premium unboxing feel. Poly gives you lower carbon, lower weight, and lower cost, with a recyclability story that keeps improving. Neither is universally the right call. It depends on what your brand is optimising for.
How to choose between a paper mailer, a poly mailer, and a compostable mailer?
It comes down to three questions: what your brand is optimising for, where you're selling, and what your customers will actually do with the mailer after it arrives.
Choose paper if:
- Kerbside recyclability is non-negotiable for your market
- The unboxing experience is central to your brand
- Your customers are unlikely to seek out a soft-plastics drop-off point
Choose PCR poly if:
- Carbon footprint is your primary sustainability metric
- You're optimising for cost and freight efficiency
- You want a high-quality print finish with matte or frosted options
- You're running automated fulfilment and need autobagger-compatible film
Choose compostable if:
- Your customers are genuinely likely to compost at home
- Compostable end-of-life story is the centrepiece of your brand's sustainability positioning
- You've confirmed composting infrastructure exists in your key markets
None is universally the better choice. Paper wins on kerbside convenience. Poly wins on carbon and cost. Compostable wins on end-of-life story where the infrastructure supports it. The right answer depends on what you're optimising for, we'll always give you the honest picture.
Why Grounded
Custom sustainable mailers engineered for impact
Certified sustainable supply chain, end to end
Mailer bags are available in GRS-certified PCR film and FSC-certified paper, supported by complete chain-of-custody documentation. This extends beyond simple material claims to offer a fully auditable supply chain. You get verified traceability across every tier rather than unsubstantiated material promises, ensuring your brand stays compliant with tightening global regulations and Extended Producer Responsibility (EPR) reporting.
Multi-country fulfilment architecture, built around where you sell
Production and shipping built around how brands actually operate. Mailers can ship direct to your DCs or sit in managed warehouses across several markets at once, drawn down as you need them rather than landing as one annual order you have to store and fund upfront. With manufacturing partners, local warehousing and regulatory teams across key regions, your packaging is specified for the market it actually lands in.
Data-driven sustainable packaging
Grounded removed the guesswork in evaluating sustainable mailer materials against one another with Scope, our proprietary Packaging LCA tool. Our 100% PCR poly mailers deliver cradle-to-grave carbon footprints around 42% lower than virgin plastic and 57–60% lower than paper alternatives. Plus, autobagger-compatible PCR film ensures your packing lines run at high speeds without bottlenecking fulfilment.
Print quality and customisation as brand leverage
Fully custom is our default. Printed mailers provide a high-performing marketing touchpoint. Grounded focuses on print quality, colour accuracy, and tactile finish, utilising rotogravure for poly film alongside flexo and litho for paper structures. Want us to match your existing mailers? No problem. Bring us your current spec - size, gauge, finish, print - and we'll reproduce it. Print quality is something we put up against anyone.
Customer proof
Mailer bags made with Grounded
Frequently asked questions
Are Grounded Packaging’s mailers recyclable?
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It depends on the material. Our poly mailers are recyclable through soft-plastics drop-off points. Our paper mailers are kerbside recyclable today. We also offer certified home or industrial compostable mailers if that's the direction your brand is heading. Recyclability infrastructure varies by market, so we'll always give you the honest picture for where you're actually selling.
What is the difference between a paper mailer and a poly mailer?
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The obvious difference between a paper and poly mailer is the material, however they also have different strengths and considerations. A paper mailer is made from renewable paper fibers, and can be made using recycled paper and FSC-certified, that can be placed directly into standard kerbside paper recycling bins by consumers. A poly mailer is constructed from durable, flexible plastic films (such as up to 100% post-consumer recycled LDPE or bio-based compostable polymers) providing superior water resistance and tear strength for soft goods.
What finishes are available on Grounded mailers?
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On poly mailers: standard, matte, and a frosted finish for brands that want a premium tactile feel. The frosted option uses a recycled CPE film and isn't something many suppliers can offer in a recycled format. On paper: white or brown kraft in a range of gsm weights, with options for expandable gusseted formats where the order needs more volume capacity.
How do I choose between compostable, paper-recyclable, and recycled plastic mailers?
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Choose Paper Mailers (Papermade) for maximum customer convenience in kerbside recycling streams. Choose Recycled Poly Mailers (Wastemade) for water-resistant, lightweight shipping with high post-consumer recycled content. Choose Compostable Mailers (Plantmade) for zero-waste apparel packaging designed to break down in compost environments.
Are Grounded mailer bags customisable in custom dimensions?
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Yes. Fully custom sizing is our default, we reproduce whatever dimensions you currently run, or work with you to find the right size for your product. There's no fixed size menu to choose from. The minimum order quantities apply: 100,000 units per unique size or design for poly, 50,000 for paper.
Can I get a sample before I commit to production?
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Yes. For custom orders, you will receive a printed digital proof and structural sample before full production begins. Nothing goes to print without your sign-off.
Build your dream mailer
Tell us what you are shipping, your target protection requirements, and the quantity you need. We will help narrow the format and available material options.
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