Poly Mailer Sizes
Poly Mailer Sizes is most useful as a specification process, not as a claim that one stock measurement fits every product. Begin with the folded product at its widest and longest packed footprint. Measure the actual pack-out, note its orientation, and separate usable internal space from the outside dimensions that affect storage, cases, shelves, or shipping. For soft goods and other non-rigid products prepared for mailing, the right size follows the product and packing method rather than a copied dimension.
Bulk pricing
From $0.38 per unit
At a 50 unit minimum. Final price depends on size, material, and finishing.
Key Takeaway
Poly Mailer Sizes should be specified from the packed product outward, not copied from a generic size. Measure the folded product at its widest and longest packed footprint, then allow for product thickness, closure seam, loading clearance, and fill level. Record usable width x length, with any gusset and closure area listed separately. HPP manufactures to the exact size ordered from 50 units, with 100 or more required for specialty rigid. Production runs from about 7 business days, depending on the product, quantity, and finishing, plus 2 to 5 business days for delivery. Call (866) 225-2112 with the dimensions, structure, quantity, and delivery destination.
Build the custom order around compression, loading direction, closure space, labels, and delivery handling. Add only the clearance required by the chosen structure, insert, and loading method, then record every measurement in a declared order. HPP manufactures to the exact size ordered from 50 units, with 100 or more required for specialty rigid. Production runs from about 7 business days, depending on the product, quantity, and finishing, plus 2 to 5 business days for delivery. Call (866) 225-2112 with the finished specification and delivery destination.
Measure the packed product for poly mailer sizes
Start with the folded product at its widest and longest packed footprint. Use the real product, final count, and intended arrangement. If the package includes an insert, wrap, booklet, divider, board, or protective layer, assemble those elements before recording the space the box must hold.
Measure more than one finished pack when product variation or hand packing can change the fit. Record the measuring units and orientation with the figures. A photo or sketch with labeled sides can prevent length, width, height, or opening direction from being interpreted differently.
Separate internal dimensions from external dimensions
Internal dimensions describe usable product space. External dimensions include the structure itself and matter for compression, loading direction, closure space, labels, and delivery handling. State which set you are supplying rather than leaving the quote team to infer it.
Use usable width x length, with any gusset and closure area listed separately. Keep that sequence on the quote request, dieline notes, artwork brief, and any packing instructions. Consistent labels keep the measured product, proposed structure, and finished package aligned.
Plan clearance, inserts, and loading space
Allow for product thickness, closure seam, loading clearance, and fill level. Clearance should come from the actual packing sequence and chosen structure. Too little can interfere with loading or closure, while unnecessary space can let the contents move and can increase the outer footprint.
Treat insert cavities and box walls as separate measurements. Define where the product touches, how it is removed, which side opens, and whether several items share the space. Those decisions set the usable dimensions more reliably than a generic chart.
Connect the dimensions to the dieline and shipping plan
A dieline turns the finished size into panels, folds, flaps, tabs, and closure areas. Final artwork should follow the approved structure so logos, copy, and required panels remain attached to the correct faces after assembly.
Check the finished external footprint against storage, shelf, master case, pallet, label, or carrier constraints that apply to the job. If one of those limits changes, review the product arrangement and internal clearance before changing a single dimension in isolation.
Specify the exact custom size for a quote
Send the product measurements, internal dimensions, desired structure, insert plan, opening direction, quantity, artwork status, finishing direction, packing method, and delivery destination. Identify any dimension that is still provisional.
Orders start at 50 units, with 100 or more required for specialty rigid. Production runs from about 7 business days, depending on the product, quantity, and finishing, plus 2 to 5 business days for delivery. Call (866) 225-2112 with the complete poly mailer sizes specification. Rush service is about 7 to 25%, depending on the job.
Frequently asked questions
What order should I use for poly mailer sizes?
Use usable width x length, with any gusset and closure area listed separately. Label the opening, front panel, or upright direction when orientation matters. Keep the same sequence in measurements, drawings, dieline notes, artwork instructions, and the quote request so each figure points to the same side of the finished package.
Should I provide internal or external dimensions?
Provide both when possible and label them clearly. Internal dimensions control product fit, inserts, and loading. External dimensions affect compression, loading direction, closure space, labels, and delivery handling. If only one set is available, state which set it is and describe the structure so the other set is not assumed.
How much clearance should I add around the product?
Set clearance from the actual product, packing method, and structure instead of applying one universal allowance. Account for product thickness, closure seam, loading clearance, and fill level. Test how the product loads, closes, and comes out, then record the usable internal space that supports those actions without unnecessary movement.
How do inserts change the required box dimensions?
Measure the insert as part of the pack-out. Record its outside size, cavity position, wall thickness, product contact points, and removal direction. The box must fit the complete insert while the cavity fits the product, so changing either element can change the finished internal dimensions.
What dimensions and details should I send for a custom order?
Send the folded product at its widest and longest packed footprint, usable width x length, with any gusset and closure area listed separately, the structure, insert or cushioning plan, opening direction, quantity, artwork status, finishing direction, and delivery destination. HPP manufactures the exact size ordered from 50 units, with 100 or more required for specialty rigid.
Why buyers order from Half Price Packaging
- Orders start at 50 units, with 100 or more for specialty rigid formats
- Free design assistance and a digital proof approved by you before production
- Free shipping across the US
- Size guides and spec tables published from real production data
- Production runs from about 7 business days, depending on the product, quantity, and finishing, plus 2 to 5 business days for delivery
- Talk to a packaging specialist at (866) 225-2112
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