Custom Reusable Mailers with a Second Strip for Returns

What is a reusable mailer?

It is a mailing bag designed for two trips. The flap is longer than usual and carries two adhesive strips, one above the other, each under its own liner.

You seal the first strip when you send the order. The customer opens the bag by tearing along a perforated line, which leaves the second strip intact on the flap.

If they need to return something, they put it back in, peel the second liner and seal the bag again. Our photos show the double strip clearly on the pale blue bag.

What size reusable mailer should I order?

Measure your largest typical order folded flat, not just one item. Returns often include the original packing, tissue or a slip, so allow some room.

Add the folded thickness to both width and length, then add around 30 mm. The extra helps customers who fold less neatly than your packing team.

Remember the flap is longer than on a standard bag, but it does not add to the space inside. Our measuring guide for packaging orders explains the basics.

What should I print on a reusable mailer?

Brand first: a logo on the front, printed in a single ink, a pair of inks or full CMYK. A strong solid colour, like the orange and green bags in our photos, helps the parcel stand out.

Then add return guidance. A short line near the flap, such as tear here and reseal with the second strip, prevents most mistakes.

Leave a clear panel for the outgoing label and another space for the return label. If both labels land in the same place, the old barcode can confuse scanners.

How do I pack a reusable mailer so it survives two journeys?

The bag has to stay in good shape after the first trip. Gentle handling at your end helps it last.

Fold items neatly, without sharp creases at the corners of the bag. Push out the air, then seal the first strip only, leaving the second liner in place.

Do not tape over the tear line or the spare strip. Tape there can rip the flap when the customer opens the bag, which ruins the return.

Pop the packing slip inside with a short reminder about the second strip. A customer who has the slip in hand when deciding on a return is far more likely to reuse the bag properly.

What mistakes do sellers make with reusable mailers?

The most common is choosing a bag that only just fits. When a customer refolds the item for a return, it is rarely as flat, and the bag may not close.

Another is skipping the printed instructions. Without them, some customers rip the bag open from the side and the second strip becomes useless.

Sellers also use the spare strip themselves by mistake, sealing both on dispatch. Brief your packing team so only the first liner is peeled. A note above the packing bench, or a quick demo for new staff, is usually all it takes to stop it happening.

Reusable mailer or reusable box?

Bags suit soft goods that can be folded. They are light, take little shelf space and keep postage low.

For shoes in their own carton, boxed gifts or anything breakable, a box built for a return trip makes more sense. See our reusable boxes made for return trips for that style.

Some brands use both. Clothing goes in the bag, and accessories or gifts go in a small reusable box with its own second seal. Keeping the same print on both makes the two formats look like one family on the doorstep.

Do reusable mailers save money?

They usually cost a little more per bag than a single-strip mailer. In return, customers do not need to find their own packaging, which means fewer badly packed returns and fewer damaged items.

Returns that arrive in your own branded bag are also easier to spot and sort when they reach you. Some shops find their goods-in team handles them faster, because every return looks the same. For a wider look at parcel costs, read our guide to lowering what you pay for UK postage.

How do I order reusable mailers?

Give us the flat size, the film colour, your artwork and the quantity. Design Your Box is a quick way to try a layout before you send files.

Prices for these bags begin at £0.25 per unit, and you receive the full figure in writing before anything goes ahead. Proofs are free, and our designers can arrange the return instructions for you.

Approved artwork goes into a 4–6 business day production slot. A tracked courier brings them to you within 2–3 business days. There is nothing to pay for delivery to a UK address.

What happens if my reusable mailers have a fault?

Maybe a strip will not stick, the print is wrong or the bags arrive damaged. Take photos and contact us within 10 days of receiving them, and we will reprint the faulty bags or give you a refund.

Test a few bags from each carton before a busy week. Seal one, tear it open, and reseal it with the second strip, just as a customer would. That quick check catches problems before they reach your customers.

Email info@ordercardboardboxes.co.uk with your order details, or reach us through WhatsApp if that is quicker for you.