Choosing the correct mailer bag size and thickness is essential for protecting your products, minimizing shipping costs, and enhancing the customer experience. If your bags are too small, you risk product damage. If they’re too big or too thin, you waste money and materials.
This guide will help you select the perfect size and thickness of mailer bags for your products — whether you’re shipping clothing, cosmetics, books, or electronics.
📏 1. Why Size and Thickness Matter
The right size ensures a snug but safe fit, while the correct thickness protects against tearing, punctures, and weather during transit. When done right, good packaging saves costs, reduces waste, and elevates your brand.
📦 2. How to Choose the Right Size Mailer Bag
Here’s a step-by-step process:
a. Measure your product accurately
Include:
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Length, width, and height
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Any extra space needed for folding or protective wrapping
b. Add tolerance space (1–3 cm)
This allows room for sealing, breathing space, or slight product variations.
c. Choose standard sizes (for cost efficiency):
| Product Type | Suggested Mailer Size (W x L cm) |
|---|---|
| T-shirts | 25 x 35 cm |
| Small books | 20 x 30 cm |
| Hoodies/jackets | 35 x 45 cm or larger |
| Multiple items | 40 x 55 cm or customized sizes |
d. Don’t oversize
Large bags can lead to wasted space, higher courier fees, and a poor unboxing experience.
💪 3. How to Choose the Right Thickness (Microns or Mil)
Thickness impacts protection and stretchability.
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1 mil ≈ 25.4 microns (µm)
Common thickness options:
| Thickness | Application |
|---|---|
| 50–60 µm | Light items: t-shirts, underwear |
| 70–80 µm | Books, small electronics, cosmetics |
| 90–120 µm | Heavy or sharp-edged items, tools |
| 120+ µm | High-value or fragile items |
Note: If shipping internationally or in bulk, consider going thicker to avoid damage.
🌱 4. Eco-Friendly Options Still Offer Protection
Don’t assume compostable or recyclable bags are less durable. Many eco-friendly materials now match or exceed the strength of traditional PE film — just ask your supplier for the test data.
👉 Explore Hanpak’s eco-friendly mailer options (internal link)
🎯 5. Other Factors to Consider
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Seal strength: Choose tamper-evident or double-seal bags for added security
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Bubble lining: For fragile goods, use padded or bubble mailers
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Custom sizing: For unique products or branding, ask for made-to-order options
👉 Contact Hanpak for custom sizes and thicknesses
✅ Conclusion: One Size Doesn’t Fit All
Selecting the right mailer bag size and thickness depends on your product type, shipping conditions, and branding needs. A few extra minutes to calculate the right specs can save you money, prevent returns, and improve your customer satisfaction.
At Hanpak, we provide a wide range of custom mailer bags, from basic poly mailers to eco-friendly compostable options — all tailored to fit your business.
For more information about Hanpak Vietnam’s plastic bag products, please contact us:
📧 Email: info@hanpak.com.vn
📞 Hotline (Mobile/WhatsApp): +84 898 545 893
Our experienced sales team is ready to assist you. Contact us today to place your order and experience the quality and reliability that Hanpak Vietnam offers.