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Custom Poly Mailers

Custom Poly Mailers

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Anyone who has handled a few rounds of online orders knows that poly mailers don’t have an easy journey. They get dragged across belts, thrown onto stacks, squeezed between boxes and sometimes land in weather that wasn’t part of the plan. At Aly Packaging UK, our custom poly mailers are built with the real conditions that are most likely to occur. Our aim is not to manufacture mailers that offer the best appeal but those that fulfill utility of clients. The ones couriers don’t advertise but every sender has seen at least once.

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What Makes Us The Top Supplier?​

Top quality prints using the latest technology

We are commercial printers with experience in Litho,
Digital, and off-set printing techniques.

Fully Personalised sizes and designs

We specialise in manufacturing bespoke boxes in
custom size and shape of your choice.

Quick Turnaround

With our printing setups across the globe, we are
capable of handling small and bulk orders alike.

Flawless Finishing with Prime Results

Aly Packaging is mainly a B2B supplier, we believe in delivering the best of the best.

Dedicated Packaging Consultants

Our dedicated team of packaging consultants are
there to help you from start to finish.

Environmentally friendly production processes

Our eco- friendly cardboard, kraft, corrugated, and rigid boxes are produced in a controlled environment.

Customise Your Custom Poly Mailers

Select Key Features & Finishes

  • Dimensions
    Custom Sizes: We only manufacture bespoke boxes. You can order your custom printed boxes according to your preferred shapes and sizes.
  • Minimum Order Quantity
    MOQ: The minimum order quantity you can expect from us is 50 Boxes.
  • Paper Stock
    Paper Stock: 250Gsm to 500Gsm (14pt to 28pt) Eco-friendly White Card or Brown Kraft, B, C, or E-flute Corrugated, or 800Gsm to 1400Gsm Rigid Hardboard.
  • Printing
    Printing Method: 1-4 Colour CMYK or Pantone Colours - Off-set, Digital, or Screen Printing – Outside or Both Sides
  • Sampling
    Sampling: Free Digital Proofing. Material Sampling and Prototype Sampling is Provided on Demand.
  • Turnaround
    Production Speed: Standard 10 Business Days, Priority 8 Business Days, Rush 6 Business Days.
  • More Info
  • Finishes & Lamination
  • Reviews

Made to Tackle the Rough Handling at Every Turn

A lot of brands don’t realise how different items behave once sealed in a mailer. Clothing traps pockets of air and makes the bag puff if the film isn’t flexible enough. Flat items curl slightly when the adhesive strip pulls inwards, while books can push corners outward and create stress marks. Hence, we make sure the seam on our personalised poly mailers not too thin, the bag tears right where the pressure sits. We work around these movements. The thickness of the material is tested so it bends without stretching too far. The adhesive strip is chosen so customers can open the bag without fighting it, but it still holds through the bumps of courier handling. Even the gloss or matte finish changes how the surface looks after a journey.

Materials Fit for Weather, Pressure and Repeated Handling

Poly mailers must take hits, moisture and friction. The material type sets the tone from the start.
  • Standard poly: a simple option for soft goods and lightweight items.
  • Recycled poly: used by brands that prioritise sustainability.
  • Heavy-grade poly: chosen when the mailer carries weight or sharp corners.
  • Bubble-lined mailers: helpful for delicate products or surfaces that scuff.
We use soy based inks for print areas and apply water based coatings when branding needs extra protection. Matte finishes hold colour calmly and reduce glare. Gloss finishes suit bold branding that needs impact at first glance.

Designs That Fit Different Shipping Routines

Some brands ship small, steady quantities. Others process dozens of orders within minutes. Each workflow needs something slightly different. If your items need return handling, we add dual-seal strips to our mailer, making the process easier. For clothing brands, we offer breathable options that don’t trap too much air inside. While for Electronics handling we reinforce seams so that devices do not push at the corners in odd ways. These might seem like small adjustments, but they change how the mailer feels when the customer receives it.

Optional Features

  • Bubble lining
  • Dual-seal returns
  • Opaque layers
  • Custom sizes
  • Matte or gloss finishes
  • Reinforced seams
  • Internal printing

Experience Based on Real E-commerce Handling

After working with a mix of clothing shops, subscription brands and small product makers, we’ve seen what goes wrong with poorly chosen mailers. Some bags wrinkle too easily. Others tear near the seal because the adhesive folds in. We’ve provided clients thicker material simply because their courier ran parcels through older machines that scraped surfaces harder. These are the types of observations that allow us to constantly improve our mailers. So whether you want to switch from bulky mailer boxes to poly mailers or wish to shift from subscription boxes to lightweight mailer solutions, we can ensure a seamless process for you and ensure that your business faces no disruptions.

Ordering That Suits Both Small Batches and Steady Flows

You can begin with low quantities of mailers so you can test thickness, sealing strength and print clarity before moving to larger runs. After confirmation, production usually takes 8-10 working days, and UK delivery is free and insured. Digital proofs or physical samples can be arranged, depending on what you need to test.

Packaging That Holds Up When It’s Out of Your Hands

Once a parcel leaves the warehouse, the mailer has to do the rest of the work on its own. At Aly Packaging UK, we produce poly mailers that hold up through the rough, uneven and unpredictable parts of the journey, keeping your brand visible and your product protected. Call: 07462 212 450 / Email: sales@alypackaging.co.uk
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