When it comes to shipping small merchandise, businesses often turn to poly mailers for their low upfront cost and convenience. However, while poly mailers may seem like a budget-friendly solution, a closer look at shipping rates and total costs reveals a different story.

At Conformer, we believe in providing smarter, more cost-effective packaging solutions. Let’s explore why poly mailers may not be as economical as they appear, the alternatives available, and how our mailers can save your business money while ensuring efficient, reliable shipping.

Are Poly Mailers Cheaper? The Hidden Costs

At first glance, poly mailers seem inexpensive—costing as little as $0.10 per mailer. But the real expense comes with postage.

Here’s the issue: 99% of poly mailers ship as Parcels, not Flats, due to their irregular shape and floppy nature. Parcel rates with USPS start at around $4.00 for lightweight packages.

Total cost for a poly mailer shipment:

• • Mailer cost: $0.10
  • Postage cost: $4.00

• Total: $4.10

While the poly mailer itself is affordable, the higher parcel shipping rate significantly impacts your bottom line. For businesses shipping hundreds or thousands of items monthly, these costs add up quickly.

What’s an Alternative to Poly Mailers?

An alternative to poly mailers is a mailer that provides a uniformly thick and flexible package—a design that meets USPS requirements for shipping as a “Flat” instead of a Parcel.

At Conformer, our custom mailers are designed to do just that. Though our mailers may cost more upfront (approximately $0.50 each), they offer substantial postage savings:

• • USPS Flat rate shipping: Approximately $2.00
  • Total cost for a Conformer mailer shipment:
    • Mailer cost: $0.50
    • Postage cost: $2.00
    • Total: $2.50

The difference is clear: with Conformer mailers, your total cost per shipment is $1.60 less than with poly mailers. Over time, those savings add up, helping your business achieve greater profitability.

Poly Mailers vs. Envelopes: Understanding the Difference

Many people use the terms “poly mailer” and “envelope” interchangeably, but they serve distinct purposes:

Poly Mailers: These are flexible, plastic mailers commonly used for shipping soft goods like clothing. However, their floppy design prevents them from maintaining a uniform thickness, which disqualifies them from lower Flat shipping rates.

Envelopes: Envelopes can include paper or rigid designs. Rigid mailers, like Conformer mailers, provide consistent thickness and flexibility, meeting USPS requirements for Flats.

Why it matters:

The difference between a Flat and a parcel is significant when it comes to shipping costs. By using an envelope or mailer that qualifies as a Flat, you can cut postage costs by nearly half.

Why Choose Conformer Mailers?

Conformer mailers are specifically engineered to provide the best of both worlds:

• Cost Efficiency: While our mailers cost more than poly mailers initially, the lower postage rates quickly offset the difference.
• Design Advantages: Our mailers are flexible yet maintain uniform thickness, qualifying them for Flat rates in many cases.
• Durability: Unlike poly mailers, which can tear or fail to protect contents adequately, Conformer mailers offer enhanced protection, ensuring items arrive intact.
• Eco-Friendliness: We prioritize sustainability, offering mailers that align with environmentally responsible practices.

Real-World Savings

Let’s break it down with an example:

If your business ships 1,000 packages monthly:

• Using poly mailers: $4.10 per shipment x 1,000 = $4,100
• Using Conformer mailers: $2.50 per shipment x 1,000 = $2,500
• Savings per month: $1,600
• Savings per year: $19,200

That’s a significant amount to reinvest in your business or support other growth initiatives.

Make the Switch to Smarter Shipping

Choosing the right mailer isn’t just about upfront cost—it’s about total cost, efficiency, and protecting your shipments. By switching to Conformer mailers, you’re not only saving money but also elevating your business with professional, eco-friendly packaging that meets shipping standards.

Ready to cut costs and improve your shipping strategy? Contact Conformer today to learn how our custom mailers can transform your shipping process and boost your bottom line.