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How to Make Custom Poly Mailers That Elevate Your Brand

  • LPS Industries
  • Aug 14
  • 3 min read

In today's competitive marketplace, your packaging is often the first impression customers have of your brand. One powerful and cost-effective way to make that impression count?


Custom poly mailers.


Whether you're shipping apparel, accessories, or lightweight products, branded poly mailers are a sleek, durable, and memorable way to deliver your goods. At LPS Industries, we specialize in designing and manufacturing high-quality custom poly mailers that do more than protect—they promote.



Why Choose Custom Poly Mailers?

Custom poly mailers aren’t just about looks—they’re a marketing tool, a protective solution, and a customer experience enhancer all in one. Here’s what makes them stand out:

  • Lightweight and cost-effective for shipping

  • Water-resistant and durable, keeping items safe

  • Fully customizable in size, shape, color, and branding

  • Ideal for eCommerce, retail, and subscription services

Let’s explore how to create poly mailers that not only meet your functional needs but also leave a lasting impression.


1. Design: Where Function Meets Visual Impact

Your design is what turns a plain package into a brand statement. Here's how to get it right:

  • Choose the right size: Select dimensions that snugly fit your product to reduce waste, avoid damage, and lower shipping costs.

  • Incorporate brand elements: Use your logo, colors, and fonts to make your mailer instantly recognizable.

  • Use eye-catching graphics: Bright colors, bold typography, and unique patterns can make your packaging pop.

  • Add a call to action: Consider a printed message like “Tag us on social” or “Scan for a surprise” to boost engagement.

With LPS Industries, our in-house design team works with you to develop packaging that balances branding, clarity, and function.



2. Printing: Bring Your Brand to Life

Professional printing ensures that your designs are vibrant, consistent, and long-lasting. At LPS Industries, we offer:

  • Full-color, high-resolution graphics

  • Matte, gloss, or custom finishes

  • Ink adhesion technology that resists smudging or fading

Trying to print on slippery plastic without the right equipment can lead to smears and inconsistent results. That’s why businesses trust professionals to deliver clean, high-impact packaging every time.



3. Materials: Choosing the Right Poly Mailer Film

Poly mailers are typically made from polyethylene (PE)—a lightweight, waterproof, and flexible material ideal for shipping non-fragile items.

When selecting materials, consider:

  • Durability: Can the mailer withstand handling, moisture, and abrasion?

  • Weight: Lightweight materials save on shipping costs without sacrificing protection.

  • Eco-friendliness: Ask about recyclable or biodegradable options to reduce environmental impact.

  • Thickness: We offer a range of gauges to match your product’s needs.




4. Assembly & Sealing Options

Once your material and print are selected, we fabricate mailers for secure, efficient use:

  • Self-seal adhesive strips: Tamper-evident and easy to close without tools

  • Tear strips: For easy customer opening

  • Custom gussets or bottom seals: For bulkier products

Need reinforced sides? Padded layers? We can engineer custom mailers to suit nearly any shipping requirement.



5. Branding That Travels

One major advantage of custom poly mailers is brand visibility. Your package isn’t just a container—it’s a mobile billboard. LPS Industries offers:

  • Custom colors to match your brand identity

  • Logo printing in high fidelity

  • QR code and promo integration for marketing campaigns

  • Branded messaging that creates unboxing excitement

Whether you're a DTC eCommerce brand or a retail giant, branded mailers add professionalism and consistency across the customer journey.


Learn more about our printing capabilities!

Why Choose LPS Industries for Custom Poly Mailers?

At LPS Industries, we combine decades of experience with cutting-edge printing and packaging technology to deliver poly mailers that perform and impress. Here’s what sets us apart:

  • Made in the USA with strict quality control

  • Low minimum order quantities or large-scale production

  • Custom film blends and thickness options

  • Sustainable packaging materials available

  • Fast turnaround times and expert support

We don’t just manufacture poly mailers—we create tailored packaging solutions that help your brand get noticed.



Ready to create custom poly mailers that truly stand out?

Contact LPS Industries today to request a quote or discuss your design ideas with our team.



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