Stop Mailers From Ripping at the Seam

Stop Mailers From Ripping at the Seam

Seam failures happen when the mailer is overfilled or the mil is too thin. Pick a mailer 1-2 inches larger than your contents on each side. Step up to 3+ mil for sharp or heavier items, or switch to bubble mailers for hard-cornered goods.

Quick facts

In-stock SKUs 9
Total options 9
Price from $8.75
Price to $19.71
Average price $14.12
Materials bubble, white, poly, corrugated, kraft
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

Seam failures on poly mailers happen when the contents push past the design fill volume, or when storage damage weakened the welded seam.

The fix

Pick a mailer with 1-2 inches of slack around your contents. Step up mil rating for sharp or heavy soft goods. Switch to bubble mailers for items with hard corners.

Alternatives to consider

Also stocked

Frequently asked

How much slack should a mailer have?

1-2 inches on each side. Overstuffed mailers put stress on the welded seam.

Can a ripped seam be re-taped?

Yes for a single trip, but integrity is compromised. Use carton tape extending 2 inches past each side of the rip.

When should I switch mailer to box?

Items over 1 lb with any hard corner — switch to bubble mailer or corrugated box.