Custom Padded Paper Mailers for Small, Delicate Items

What are padded paper mailers?

A padded paper mailer is a kraft envelope with a built-in cushion. Inside the outer paper sits a second layer of shaped paper that squashes gently under pressure.

Two linings are common, and both are made from paper rather than plastic film. Honeycomb paper has a net of small cells that open out, and fluted paper has rows of ridges, a little like corrugated board.

You can see both types in the photos on this page, through the cut-out windows. Either one spreads a knock across a wider area before it reaches the product.

What size padded paper mailer do I need?

Padded mailers are sized by their flat outside measurements. The cushioning takes up some of the inside, so the usable space is smaller than the paper size.

Measure your item's length, width and thickness. Add the thickness, plus a margin for the padding and the flap, to both the width and the length.

A paperback 130 × 200 × 20 mm usually fits a 180 × 260 mm mailer. When in doubt, send us the product measurements and we will suggest a size.

For more on taking measurements, see our guide to measuring before you order.

Honeycomb or fluted paper padding?

Honeycomb padding is soft and springy. It wraps around odd shapes, which suits jewellery boxes, small bottles and anything with a curve.

Fluted paper padding is firmer along the ridges. It keeps flat items such as books and diaries from bending, and resists punctures from sharp corners.

Both are paper, so the whole mailer is one material. That keeps disposal simple for the person who receives it. Tell us what you post and we will suggest the lining that fits best.

Can padded paper mailers be printed?

Yes. The outer kraft takes one colour or two colour print well, and full colour CMYK is possible for brighter designs.

An all-over colour, such as the orange or yellow shown in our photos, makes the parcel easy to spot on a doormat. A brown kraft bag with a black logo looks plain and practical.

Keep the front centre clear for the address label, and put any return address on the back or the flap. The padded face can feel slightly uneven, so very fine text is best placed near the edges.

What are the common mistakes with padded mailers?

Choosing a mailer from the paper size alone is the main one. A 220 × 340 mm mailer will not take a 220 × 340 mm item. The padding and seams use some of that room.

Another is posting glass or ceramics in a padded envelope. Those need a box, an insert and some void fill.

Overfilling is the last. A bulging mailer strains the seal and can split along the base in transit. If an item only just fits, move up one size rather than forcing it in.

When is a box better than a padded mailer?

If the item is heavy, rigid and breakable, a box wins. A padded mailer cushions small knocks but does not stop crushing from parcels stacked on top.

For anything like a mug, a candle jar or a glass bottle, look at our mailers built for fragile items. They use a corrugated box with inserts that hold the product still.

For light, flexible or flat items, a padded mailer is usually cheaper to buy and to post than a box of the same footprint. It also packs faster, since there is nothing to fold and no tape to cut.

Do padded paper mailers keep postage costs low?

Usually, yes. They are thin and light, so many orders fit a large-letter or small-parcel band rather than a bigger one. Check the thickness limit for each band, as a padded mailer with a chunky item can creep over it.

Keep the mailer as small as the product allows. Even 20 mm extra on each side can push a parcel into the next price step. Our guide to trimming the cost of UK postage has more on this.

How do I order padded paper mailers?

Send the flat size, lining type, outer colour, print and quantity. If you are not sure of the size, send the item measurements instead and we will work it out.

Prices start at £0.25 per unit, confirmed in a written quote before you commit. You get free help with artwork and a free digital proof to check.

Once you say yes to the proof, we take 4–6 business days to make the mailers. Tracked shipping follows and lands in 2–3 business days. We cover the delivery cost for every UK order.

What if my padded mailers arrive damaged or wrong?

Found a misprint, a torn seam or another defect? Take a few photos and get them to us no later than 10 days after the mailers arrive. Those mailers are then reprinted or refunded, whichever you prefer.

It helps to open one bundle as soon as the order lands. Check the print, the seal strip and the padding on a handful of mailers, then store the rest flat and dry.

Our inbox, info@ordercardboardboxes.co.uk, and our WhatsApp line are both checked by the same team.