Resources & Packaging Guides
Expert tips, material comparisons, industry news, and how-to guides to help you choose the right packaging, cut costs, and ship smarter.
How Bubble Mailers Are Manufactured
A practical guide to bubble mailer manufacturing — from raw materials to finished product, what separates quality suppliers from cheap ones, and what wholesale buyers should ask before placing a large order.
Kraft vs. Poly Bubble Mailers: Cost & Use Cases
Side-by-side breakdown of kraft and poly bubble mailers — durability, cost per unit, eco-impact, print options, and which material fits which e-commerce use case.
Custom Printed Mailers for E-Commerce Brands
How branded packaging drives repeat purchases, what print technologies work best at different volumes, and how to budget for a custom mailer program without over-ordering.
USA vs. China Packaging Manufacturing: True Cost Analysis
Ocean freight, tariffs, quality variation, and lead times — a data-driven breakdown of why near-shore manufacturing often beats overseas for US-based e-commerce businesses.
Eco-Friendly Packaging: Our Recycling Guide & Circular Economy Commitment
A full breakdown of which Atlas Pack USA products are recyclable, how to recycle them correctly, and how we're working toward a circular supply chain.
Packaging Tips at a Glance
Answers to the questions we hear most from e-commerce businesses and warehouse managers.
How to Choose the Right Mailer Size
Oversized mailers waste money on postage and materials. Undersized ones damage goods. Here's the simple rule: measure your product's longest dimension and add 2–3 inches for cushioning and the peel-seal flap. Standard sizes (6×10, 8.5×12, 10.5×16) cover 80% of e-commerce SKUs.
Poly vs. Kraft: Which Should You Stock?
Poly mailers are 100% waterproof and cheaper per unit — ideal for apparel, soft goods, and anything that can survive light flex. Kraft mailers signal premium unboxing, are paper-recyclable, and work well for books, accessories, and beauty products. Most operations stock both.
When to Use Mailers vs. Corrugated Boxes
Use bubble mailers for lightweight items under 2 lbs that can tolerate some flex — clothing, documents, small accessories. Switch to corrugated boxes for anything rigid, heavy (2 lbs+), fragile, or that requires dimensional packaging. Boxes cost more but protect better.
Reducing Shipping Costs with Better Packaging
Dimensional weight pricing means oversized packaging costs you even on light items. Switching to the right-size mailer or flat poly bag can cut per-shipment costs by 15–30%. Combine with lightweight stretch film over corrugated where possible to reduce billable weight.
Still have questions about the right packaging?
Our team has helped hundreds of e-commerce brands and warehouses find the right materials at the right price. Just ask.