packagingpoly-mailersboxes
Poly Mailers vs Boxes: When to Use Each
Choose the right packaging type to minimize costs and protect products.
January 9, 20262 min read34 views
Poly Mailers vs Boxes Guide
Choose optimal packaging for each product type.
When to Use Poly Mailers
| Product Type | Poly OK? |
|---|---|
| Clothing | Yes |
| Soft goods | Yes |
| Books (soft) | Maybe |
| Electronics | No |
| Fragile items | No |
Cost Comparison
| Package | Material | Shipping (1 lb) |
|---|---|---|
| 10x13 poly | $0.15 | $4.50 |
| 8x6x4 box | $0.45 | $5.80 |
| Padded mailer | $0.35 | $4.80 |
DIM Weight Advantage
Poly mailers avoid DIM weight calculations:
- No rigid dimensions
- Charged by actual weight only
- Savings: 20-40% on lightweight items
Protection Levels
| Protection | Poly | Bubble Poly | Box |
|---|---|---|---|
| Crushing | Low | Medium | High |
| Moisture | High | High | Medium |
| Puncture | Low | Medium | High |
| Stacking | Low | Low | High |
Size Selection Guide
| Product | Poly Size | Box Alternative |
|---|---|---|
| T-shirt | 10x13 | 10x8x2 |
| Shoes | 14x19 | 12x9x4 |
| Light jacket | 12x15 | 14x10x4 |
| Accessories | 6x9 | 6x4x2 |
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