Choosing the right mailer is one of the most important packaging decisions a brand makes. It affects sustainability, customer experience, shipping costs, product protection, and ultimately your brand image. Two of the most common options in ecommerce are kraft mailers and polymailers. Although they are often grouped into the same category, they behave very differently when in use. Understanding those differences is the key to choosing the best option for your brand.

Below is a clear and unbiased look at how each mailer performs, when each one works best, and how a business can choose the right option without compromising sustainability or efficiency.

What Are Kraft Mailers and Polymailers

Both mailers serve the same purpose. They protect and transport lightweight to moderately durable products from point A to point B. The difference comes down to materials and construction.

Kraft mailers are paper based mailers made from unbleached Kraft paper. They are known for their natural texture, clean appearance, and curbside recyclability in most regions. Some Kraft mailers include an internal layer of padding made from recycled paper fibers, though for this article we are focusing on unpadded Kraft mailers only, since padded varieties create a different comparison.

Polymailers are flexible envelopes made from polyethylene (plastic) film. They are water resistant, tear resistant, and extremely light. They have become the default choice for many ecommerce brands because they are durable under pressure and inexpensive to ship.

Because kraft is paper and poly is plastic, these two mailers differ by more than performance. They represent two distinct approaches to packaging. One is renewably sourced and easy to recycle. The other is lightweight, strong, and efficient in transit. Neither is inherently better, but each excels in different ways.

Durability and Product Protection

One of the strongest advantages of polymailers is their durability. Polyethylene film naturally stretches, which helps prevent tears and punctures. This makes poly an excellent choice for soft goods like clothing, accessories, fabric based products, and textiles. Polymailers are also naturally moisture resistant, which helps protect shipments during wet weather or warehouse handling.

Kraft mailers offer a different kind of protection. They do not stretch, but they have a structured form that helps keep small items organized and prevents bending. Kraft is well suited for stationery, small rigid goods, books, or branded experiences where presentation matters. Kraft paper absorbs moisture rather than repelling it, so while it performs well in dry conditions, it is not as resistant to humidity or water exposure as poly.

In short, poly wins for toughness and weather resistance. Kraft wins for structured protection and presentation.

Environmental Impact and End of Life

This is where the two mailers differ the most. Kraft mailers are made from trees, which is a renewable resource, and are widely accepted in curbside recycling programs. Their fibers can be recycled several times. This makes Kraft a strong choice for brands that prioritize circularity and want packaging that fits consumers’ expectations for eco friendly materials.

Polymailers, on the other hand, are made from polyethylene. Poly itself is technically recyclable, but most curbside programs do not accept it because it behaves like a film rather than a rigid plastic. In many regions, consumers would need to bring polymailers to store drop off programs to ensure proper recycling, and participation rates for these programs vary. Many consumers do reuse polymailers for returns or secondary shipping, which is great, but reuse depends heavily on consumer habits.

Neither material is perfect, but kraft has a more accessible recycling pathway for most customers. Poly offers lightweight shipping efficiency, which reduces emissions during transportation. 

Shipping Weight and Cost Efficiency

Polymailers are extremely lightweight. This matters because even small weight reductions can save money at scale and reduce carbon emissions from shipping. Poly’s flexibility also helps minimize dimensional weight by allowing the mailer to compress around its contents. These two factors make poly a popular choice for high volume apparel brands where every ounce matters.

Kraft mailers are slightly heavier and more rigid, which can increase shipping weight for certain products. However, they offer a more premium opening experience, which some brands value more than a modest cost difference. The rigidity of Kraft also keeps the mailer’s shape consistent, which can be beneficial for flat or delicate items.

If shipping efficiency is your top priority, poly holds the advantage. If brand experience and recyclability matter more, kraft is the stronger choice.

Brand Presentation and Customer Perception

Packaging shapes consumer identity. In recent years, consumers have increasingly associated paper based packaging with sustainability. Even without printed messaging, a kraft mailer communicates a natural and responsible look. It feels intentional and aligns with the expectations of eco conscious shoppers.

Polymailers can also be customized, often more flexibly because printing on film allows for vibrant colors. Many fashion brands use poly for colorful branded experiences. However, some customers associate plastic packaging with waste, even when the material is technically recyclable, and in many cases were made from recycled plastic.

Neither option is inherently better for branding. The right choice depends on your identity. If you want a clean, sustainable, minimalist aesthetic, kraft reflects that. If you want bold designs and durable color reproduction, poly can deliver.

When to Choose Kraft vs Poly Mailers

Choose kraft mailers when:

• Your customers value recyclability

• You want packaging that aligns with eco friendly branding

• Your products benefit from a structured mailer

• You ship items like stationery, prints, beauty products, accessories, books, or small rigid items

Choose polymailers when:

• You ship soft, flexible, or moisture sensitive items

• You need the most lightweight and cost efficient option

• You want a highly durable mailer for rough handling

• Your branding requires bold printing and full color designs

Some brands end up using both mailer types in different situations. The most sustainable choice is the one that aligns with your product’s needs while minimizing waste.

Final Thoughts: Choosing Responsibly for Your Brand

Understanding the strengths of kraft and polymailers helps brands choose the right option for each product type. Sustainability is not about replacing every material with paper. It is about making informed choices that reduce environmental impact while maintaining product protection and customer experience.

If you want help choosing the best mailer for your products, EcoPackables offers expert guidance along with customizable, sustainably minded packaging solutions. Whether you need responsibly sourced Kraft mailers, lightweight poly solutions, or a full packaging strategy, our team can help you build a packaging program that is efficient, thoughtful, and aligned with your brand’s values.