Fix Mailers That Tear During Shipping

Fix Mailers That Tear During Shipping

Mailers tear when the mil is too thin or sharp corners press against the outer skin. Step up to 3 mil poly mailers, use bubble mailers for sharp-cornered items, or add a chipboard stiffener for flat goods.

Quick facts

In-stock SKUs 12
Total options 12
Price from $8.75
Price to $36.34
Average price $18.77
Materials white, bubble, poly, kraft, corrugated
Strengths ECT-32
Mil thicknesses 2.5
Pack quantities 25, 50, 100

In-stock options

When to use

  • Fixing a recurring damage, cost, or throughput issue.
  • Spec'ing corrective materials before peak season.

The problem

Mailers tear when the mil rating is too thin for the contents, when sharp corners press against the outer skin, or when storage damage weakened the seams before packing.

The fix

Step up to 3 mil poly mailers. For sharp-cornered items, switch to bubble mailers or add a chipboard stiffener. Rotate inventory so stored mailers don't age in warehouse damp.

Alternatives to consider

Also stocked

Frequently asked

What mil prevents tears on soft goods?

3 mil is the shipping standard for soft goods; 2 mil is retail-only. For books or mixed SKUs, step up to 4 mil or switch to bubble mailers.

Chipboard stiffener — does it help?

For flat goods (postcards, photographs, art prints) — yes. A piece of chipboard between the item and the mailer wall prevents both bending and skin punctures.

Should I double-mailer high-value items?

For sub-$100 ecommerce, a single 3 mil mailer is enough. Higher-value items benefit from a rigid literature mailer or a corrugated box.