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Listed below are several different ways of packaging mailers.

Bulk Packed Loose

  • Promotional mailers and cut sheet self mailers can be packed loose in a carton.
  • They can be packaged with or without chipboard inserted between a specified quantity of sheets.
  • Bulk packing saves time in not having to open wrapped packages when processing a large quantity of mailers.
  • Bulk packaging is the least expensive packaging option.

Plastic Wrapping

  • Promotional mailers and cut sheet self mailers can be wrapped and sealed in plastic shrink film.
  • They can be wrapped in any specified quantity.
  • A chipboard insert can be added to each package to help prevent the sheets from curling.
  • Plastic wrapping protects the sheets from potential damage.
  • It protects the mailers from taking on excess moisture.


Fiber Cartons

  • Promotional mailers and cut sheet self mailers can be packaged in fiber cartons, sometimes referred to as "inner cartons".
  • Fiber cartons help to protect the product from damage.
  • They help to prevent sheets from curling.
  • Fiber carton packaging is more expensive than bulk packed or plastic wrapped.


Note: Mailers, especially any that will be running through a laser printer, that are stored outside of a carton should be plastic wrapped or packaged in fiber cartons. This will protect the sheets from damage and from taking on excess moisture, which will cause curling. Temperature, humidity, and direct sunlight can affect the appearance and life of the product.

Continuous Mailers

  • Continuous mailers are fanfolded and put into a carton that is only slightly larger than the fanfolded stack.
  • The continuous mailers should be tight in the carton but not tight enough to cause the mailer to buckle. Packing the cartons in this manner will prevent mailers from shifting in the carton during shipping.


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