The right size.
Considered protection.
Your delivery.

A technical overview of paper envelopes and e-commerce mailers: materials, construction, dimensions, closures and printing.

Technical information

Minimum order quantity

• Unprinted stock products depend on envelope type and pack size
• Custom paper envelopes and mailing bags: usually from 2,000 pieces
• Short digitally printed runs: selected constructions from 50 pieces
• The exact minimum depends on dimensions, material, construction, printing and manufacturer

Dimensions and construction

• Kraft mailers can be flat or expandable to accommodate the contents
• Block-bottom paper mailing bags with side gussets suit clothing, textiles and other bulky shipments
• Typical block-bottom mailing bag sizes range from approximately 190 × 300 mm to 360 × 560 mm
• Paper-padded envelopes include C5, B5, C4, B4 and E4 formats
• Selected padded constructions can include expansion of up to approximately 50 mm
• Rigid paper or cardboard envelopes protect flat goods from bending and surface damage
• Select dimensions and construction according to shipment size, thickness, weight and protection needs

Materials

• Kraft mailers: for example 135 g/m² kraft or another grammage suited to the construction
• A paper-padded envelope’s outer layer may use 140 g/m² recycled paper
• The paper cushioning layer may use 120 g/m² recycled paper
• The inner layer may use, for example, 90 g/m² manila paper
• Block-bottom mailing bags use kraft paper, including FSC®-certified options
• Brown and white papers made from virgin or recycled fibre
• Grammage and layer count selected for shipment weight, construction and transport conditions

Printing options

• Kraft mailers: flexographic printing usually in up to three colours
• Paper-padded envelopes: flexographic printing usually in up to two colours
• Logos, text, patterns, handling instructions and promotional messages
• CMYK and Pantone availability depends on material, process and quantity
• Digital printing suits shorter runs and detailed or changing designs
• Colour count, print area and achievable colours are confirmed before production

Finishing

• A self-adhesive closure strip seals quickly without extra tape
• Two adhesive strips allow shipping and returns in the same package
• An integrated tear strip or tear thread simplifies opening
• A serrated or otherwise finished opening edge helps make handling safer
• Paper padding protects against impacts, rubbing and surface damage
• Depending on the product, side gussets, a block bottom or a stiffening cardboard layer can be added

Lead times

• Stock products depend on availability and quantity
• Production times for custom printed mailers are confirmed after specification and artwork approval
• Timing depends on construction, dimensions, material availability, printing and quantity
• New constructions, samples or production tooling require additional preparation time

Artwork files

• Preferred vector formats: PDF, AI or EPS
• Place artwork on the manufacturer’s approved drawing or dieline
• Convert text to outlines and supply images at the required resolution
• Specify Pantone references where applicable
• Approve the artwork proof, print area, colours and construction before production

Applications

• E-commerce orders and courier shipments
• Clothing, textiles and accessories
• Books, printed materials and documents
• Cosmetics, small goods and gifts
• Spare parts and other products needing protection against rubbing or impacts
• Return-ready e-commerce packaging

Paper envelopes and e-commerce packaging: choosing a mailing solution

Paper envelopes and e-commerce packaging offer lightweight, professional-looking solutions for sending documents, clothing, books and smaller products. Options include kraft paper mailers, paper-padded envelopes, rigid cardboard envelopes and block-bottom paper mailing bags with side gussets.

Select packaging according to shipment dimensions, thickness, weight and protection needs. Paper mailers can reduce plastic use and suit businesses seeking secure shipping, convenient handling and a branded appearance.

Materials and constructions

Kraft paper mailers suit documents, clothing, textiles and other non-fragile shipments. Kraft paper provides good tear resistance and a natural appearance, but grammage and construction must be selected for shipment weight.

Paper-padded envelopes contain a paper cushioning layer that helps reduce impact, rubbing and surface damage. They suit cosmetics, small devices, books, handmade products and other goods needing more protection than an ordinary envelope.

Block-bottom paper mailing bags with side gussets suit bulkier products because they expand to accommodate shipment thickness. Rigid paper or cardboard envelopes help protect documents, printed materials and other flat products against bending.

Dimensions, closures and returns

Envelopes and mailing bags come in standard sizes or are made to fit the product. The right format restrains movement, reduces unnecessary void fill and uses transport space more efficiently.

A self-adhesive strip enables fast closure without separate tape. A two-strip construction suits e-commerce: the second strip lets customers reuse the package for returns. An integrated tear strip or tear thread makes opening easier.

Logo printing and branded mailers

Printed paper envelopes can carry your logo, text, pattern, handling instructions or full design. Flexographic printing mainly suits larger runs and simpler single- or multicolour designs. Digital printing enables shorter runs and more detailed or frequently changing artwork.

Brown kraft gives a natural appearance; white paper enables brighter colours and stronger contrast. Process, colour count and print area are selected according to material, construction, artwork and quantity.

Applications

In e-commerce, paper mailers are used for clothing, textiles, accessories, cosmetics and small goods. A return strip simplifies returns and improves convenience.

For books, printed materials and documents, flat or stiffened cardboard envelopes help reduce bending. Paper-padded envelopes suit products needing extra protection without a corrugated box.

Plastrum as your B2B paper mailer partner

Plastrum helps select material, construction, dimensions, closure and printing. We can compare stock products with custom envelopes, mailing bags and return-ready e-commerce packaging.

We serve B2B customers in the Baltic and Scandinavian markets, helping prepare projects from technical specifications and artwork checks through to production and delivery.

Frequently asked questions

Which paper envelope suits a delicate product?

A paper-padded envelope helps protect against impact, rubbing and surface damage. Very fragile products may need stronger internal protection or a corrugated box.

Can mailers carry our company logo?

Yes. Envelopes and mailing bags can carry logos, text, patterns or a full design. Printing process and colours depend on material, construction and quantity.

Can a paper mailer be reused for returns?

Yes. Two adhesive strips allow the customer to reseal the package after opening and use it for a return.

When should I choose a block-bottom mailing bag?

A block bottom and side gussets suit bulkier products such as clothing and textiles. The expandable construction accommodates thickness better than a flat envelope.

Can paper always replace a plastic courier bag?

Not necessarily. Paper mailers mainly suit dry transport conditions. For prolonged moisture exposure, high tear loads or demanding transport, select materials and construction for the specific supply chain.