The Ultimate Guide to Shipping Poly Mailers with UPS in 2024

In today‘s increasingly e-commerce driven world, businesses of all sizes rely on shipping carriers like UPS to get their products to customers quickly, safely and affordably. While cardboard boxes are the default packaging choice for many, more shippers are discovering the benefits of lightweight yet protective poly mailers – especially for sending non-fragile items.

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As a leading shipping provider, UPS is happy to accept packages in poly mailers as long as the labels can be securely attached. But before you start stuffing orders into those plastic envelopes, there are a few important things to know to ensure a smooth shipping experience for you and your customers.

In this expert guide, we‘ll walk through everything you need to know about using poly mailers for your UPS shipments in 2024 – from what to ship in them and how much they cost, to where to buy them and how to properly pack and label your mailers. Plus, I‘ll share some pro tips I‘ve learned over my years of advising e-commerce retailers.

Let‘s jump in!

What Items Can You Ship in Poly Mailers via UPS?

While boxes provide more structure and protection, poly mailers are ideal for shipping a variety of products that are lightweight and not prone to damage. Some common items that can be safely shipped in poly mailers include:

  • Clothing and accessories
  • Fabric items like sheets, curtains, towels
  • Books, magazines and paper goods
  • Pre-packaged food or beauty products
  • Vitamins and supplements in sturdy bottles
  • Shoes
  • Phone cases
  • DVDs and video games
  • Small electronics cables or accessories

On the other hand, you‘ll want to avoid using poly mailers for anything fragile like glassware, ceramics, and electronics devices. Poly mailers also aren‘t suitable for most perishables or high-value items like jewelry or collectibles. If you‘re unsure if your product requires more robust packaging, err on the side of caution and use a box.

Benefits of Using Poly Mailers for UPS Shipping

There are several advantages to choosing poly mailers over boxes for your eligible shipments:

  1. Lower shipping costs – Poly mailers weigh less than boxes, which can significantly reduce your UPS shipping fees, especially for lightweight items. Exact savings will vary based on weight and distance, but switching to poly mailers saves some businesses 50-75% per shipment.

  2. Cheaper packaging costs – Poly mailers are very inexpensive, often costing just pennies each. Buying in bulk quantities lowers the price further. You can get free poly mailers directly from UPS as well (more on that later).

  3. Faster packing – Unlike boxes that need to be taped and assembled, you can quickly stuff a poly mailer, peel the adhesive strip, and stick on a label.

  4. Space saving – Poly mailers lie flat, making them easy to store, even in small spaces. No more towers of bulky boxes taking up precious square footage!

  5. Customizable – Poly mailers come in various colors and can be custom printed with your logo and branding for a professional look. Some retailers find this increases customer excitement and brand loyalty.

  6. Eco-friendly options – If sustainability is important to your brand, you can find poly mailers made from recycled plastic. These are often reusable and recyclable as well.

Where to Buy Poly Mailers for UPS Shipping

You can purchase poly mailers at office supply stores, shipping retailers, and even big box stores like Walmart. However, the most convenient and affordable options for UPS shippers are:

  1. UPS website – If you have a free UPS My Choice account, you can order poly mailers and other supplies from the Packaging and Shipping Supplies section of the UPS website. Flat poly mailers, bubble padded mailers, and expansion mailers are available in various sizes at no cost. There are order limits but they are fairly generous.

  2. Uline – This shipping supply company offers a huge assortment of poly mailers, often at the lowest bulk prices. You can find heavy-duty, colored, and custom printed options.

  3. Amazon – The mega-retailer carries many affordable poly mailer options, with the added benefit of quick Prime shipping. Be sure to check reviews and size specs before ordering.

How to Package Orders in Poly Mailers for UPS

Proper packaging is essential to ensure your products arrive intact and your customers stay happy. Follow these steps when preparing an order to ship in a poly mailer via UPS:

  1. Choose the right size – Select a mailer that fits your item with a little extra room, about 2 inches on each side. You don‘t want the product to be swimming in the package, but a too-snug fit can cause damage.

  2. Consider padding – For any semi-fragile items, add some cushioning inside the mailer, like bubble wrap, packing peanuts or air pillows. This is especially smart if the item may shift around in transit.

  3. Seal completely – After placing your item inside, remove the adhesive strip and fully seal the top flap of the mailer. Reinforce the seal with clear packing tape for heavier items or longer journeys.

  4. Attach the UPS label – It‘s critical that your shipping label is securely adhered and scannable. Remove the backing of the adhesive label and firmly stick it to the largest, flattest side of your sealed poly mailer. Avoid placing the label on any seams or edges. If needed, cover the entire label with clear tape to prevent peeling or damage.

  5. Double check – Before sending your mailer off, give it one last inspection. Have you included all ordered items and necessary packing slips? Is the label completely adhered and readable? Did you get the right shipping service level? A moment of caution can prevent a lot of headaches later!

How Much Does It Cost to Ship a Poly Mailer with UPS?

As with any UPS shipment, the exact cost to send a poly mailer depends on the weight, dimensions and distance it‘s traveling. Lighter, smaller packages going short distances will be your cheapest options.

To give you a general idea, sending a 12 x 15" flat poly mailer weighing 1 lb. from New York to Los Angeles would cost about:

UPS Ground (4-5 business days): $10.12
UPS 3 Day Select (3 business days): $23.76
UPS 2nd Day Air (2 business days): $35.15
UPS Next Day Air Saver (next business day): $84.13

Adding a little weight or dimensions to your mailer can dramatically increase these base rates, so it pays to keep your packaging compact and lightweight.

One big perk of using poly mailers is that they‘re so inexpensive, they won‘t add much to your total shipping costs. You can order UPS poly mailers in many sizes for free if you sign up for a UPS My Choice account on their website. Otherwise, you can buy a pack of 100 for around $10-$25 depending on size and specs.

Before you slap on that shipping label though, don‘t forget to look into UPS business shipping discounts, which can slash your rates by up to 50%. If you frequently ship similar types of packages, their Simple Rate flat-fee pricing may also help you save.

Other UPS Poly Mailer Shipping Tips and Considerations

A few other things to keep in mind when using poly mailers for your UPS shipments:

  • Aim to keep your mailer under 1 pound to avoid big jumps in pricing. You may need to use lightweight infill for protection rather than heavy materials.

  • If you‘re shipping any liquids or items containing batteries, be sure they are properly secured and labeled per UPS guidelines. When in doubt, place these items inside a sealed plastic bag as well.

  • Poly mailers are great for international shipping since they‘re so lightweight. Just be sure you have the proper customs forms and documentation! UPS International Shipping Assist can help you navigate the process.

  • Always avoid using poly mailers for hazardous or prohibited items like aerosols, firearms and perishables. Review the full list of UPS shipping restrictions.

  • Consider insuring high-value shipments, since poly mailers don‘t provide as much protection as boxes. UPS Capital Insurance Agency can cover your packages.

  • While not required, adding a suffocation warning to any poly mailer over 5" in diameter can enhance safety. You can find downloadable labels on the UPS website.

-UPS does not recommend reusing poly mailers, so it‘s best to use a new one for each shipment. However, you can purchase 100% recyclable mailers so customers can dispose of them sustainably after use.

The Bottom Line on Shipping Poly Mailers with UPS

Don‘t let their lightweight, unassuming appearance fool you – poly mailers can be powerhouse packaging for many types of UPS shipments. As long as your items aren‘t too large, heavy or fragile, you can likely send them in poly mailers and save substantially on shipping and supply costs.

Just remember to choose high-quality, well-fitting mailers, pad contents as needed, and always affix your labels securely and completely. With these best practices and a little know-how, poly mailers can help your small business grow by keeping your fulfillment process speedy and spending in check.

Have any other questions about using poly mailers for your UPS shipments? The packaging experts at UPS are always ready to help at 1-800-PICK-UPS or via live chat on ups.com.

Happy shipping!