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MANUFACTURING

Inside the manufacturing process.

From film handling to bag conversion and final packing: a closer look at the stages behind a self-sealing mailer.

AI-generated process illustration — replace with verified factory photography.
01

Film handling

The film structure and specification are set around the intended packing requirement.

02

Bag conversion & sealing

Film is formed and sealed to the agreed dimensions and closure configuration.

03

Inspection & final packing

Dimensions, appearance and packing are reviewed against the approved specification.

02 / FUNCTIONAL DETAILS

Small details. A better-packed parcel.

Specify the bag around the product, the packing line and the journey to the customer.

Self-sealing closure
01Self-sealing closure
PEEL · FOLD · SEAL

A cleaner close. A simpler packing step.

A peel-and-seal flap brings the closure into the bag itself. Match the adhesive, release liner and flap length to the way your team fills, closes and stores each parcel.

  • Choose the closure around your dispatch and returns process.
  • Check the seal on a filled bag under expected storage conditions.
  • Agree whether opening should be permanent or resealable.
Discuss your closure
02Heat-sealed side seams
CONSTRUCTION & CONVERSION

Strength starts at the edges.

Side seams are part of the complete bag construction. Review the film, seam width and packed load together, particularly where corners or uneven contents put pressure on the edges.

  • Assess seam consistency on representative finished samples.
  • Include the packed weight and any sharp product edges.
  • Define the inspection method and acceptance criteria.
Review bag construction
03Opacity & product privacy
APPEARANCE & PRIVACY

Keep the contents out of sight.

An opaque outer pack helps conceal the product inside. Film colour and construction affect the result, so assess a filled sample under the lighting and handling conditions relevant to your shipment.

  • Review opacity on both printed and unprinted areas.
  • Consider product outlines as well as show-through.
  • Match surface finish with your shipping-label requirements.
Discuss opacity requirements
04Usable size & flap allowance
DIMENSIONS & PACKING FIT

A better fit begins with the packed product.

Start with the item in its final folded or boxed condition. Keep usable bag dimensions separate from the closure flap, allowing room to insert the product and close the bag without strain.

  • Record usable width, usable length and flap separately.
  • Allow for product thickness, inner wrapping and handling.
  • Approve the fit with a physical packed sample.
Plan your bag dimensions
03 / APPLICATIONS

Made around the way you ship.

FASHION & SOFT GOODS

From folded garment to ready-to-ship parcel.

Clothing, knitwear and soft accessories need a practical outer pack that suits the folded product. Build the brief around presentation, privacy and the way your team handles individual orders.

  • Match usable dimensions to folded items and multi-item orders.
  • Consider tissue, inner bags and return instructions.
  • Review colour, opacity and closure on a packed sample.
Discuss apparel mailers
ONLINE BRANDS & RETAIL

Packaging that fits the daily order mix.

A useful mailer range follows your product assortment. Plan a manageable set of sizes, leave a clear area for shipping labels and check how printed branding works across different order formats.

  • Group products by packed size and protection needs.
  • Reserve space for labels, barcodes and order identification.
  • Separate launch quantities from expected repeat demand.
Explore e-commerce packaging
POSTAL & PARCEL DISPATCH

Specify the bag for its delivery journey.

Postal bags, courier bags and mailing bags can describe overlapping uses. State the contents, packing method and carrier requirements so the actual construction is clear before a quotation is prepared.

  • Check label readability and attachment on the chosen film.
  • State the packed weight and the handling route.
  • Clarify when you need cushioning or a separate postal sack.
Discuss postal packaging
FULFILMENT & CONTRACT PACKING

Make the pack work at the packing station.

For fulfilment teams, packaging has to fit the workflow as well as the product. Consider bag opening, sealing, labelling and replenishment together when planning recurring wholesale supply.

  • Share manual or automated packing requirements.
  • Agree bundle counts, carton labels and storage space.
  • List quantities by size, client artwork and delivery location.
Plan fulfilment supply
04 / MATERIAL & CUSTOMISATION

Build the specification, layer by layer.

MATERIAL STRUCTURE

Specify performance before choosing a gauge.

Film thickness is one part of the specification. Review the material structure against the contents, load, opacity and closure requirements, then assess a finished sample before approving bulk supply.

  • State the packed weight and required handling performance.
  • Define thickness units and how the film will be measured.
  • Review film, seams and closure as a complete pack.
Discuss film requirements
COLOUR & SURFACE

Set a consistent look for your mailing bags.

A matt or gloss finish changes the feel and appearance of the pack. Use a physical reference where colour matters, and consider the underlying film and final print together during sample review.

  • Provide a colour reference and a preferred surface finish.
  • Check appearance under agreed viewing conditions.
  • Test the chosen shipping label on the finished surface.
Explore colour and finish
CUSTOM PRINTED MAILERS

Turn brand artwork into a clear print brief.

Bring artwork, print area and bag dimensions into one review. A proof should show where the design sits relative to seams, the flap and the label area before a printed sample is agreed.

  • Provide artwork files, colour references and print sides.
  • Mark clear space for labels and closure zones.
  • Confirm proof approval, sample scope and setup charges.
Discuss custom printing
MATERIAL SOURCING

Ask for the evidence behind the material.

If recycled content is part of your brief, define the requested proportion and the supporting documentation you need. Review appearance and performance on the proposed material before approving it.

  • Clarify the source and basis of the recycled-content claim.
  • Request documentation tied to the proposed material.
  • Confirm local collection guidance before adding disposal wording.
Review material options
05 / SAMPLE TO PRODUCTION

A clear path from brief to bulk order.

  1. 01

    Share your brief

    Product, usable bag size, quantity, artwork and delivery destination.

  2. 02

    Review specifications

    Agree the material, thickness, closure, print and packing requirements.

  3. 03

    Approve a sample

    Check fit and finish. Distinguish a digital proof from a physical sample.

  4. 04

    Confirm production

    Record the approved specification and order-specific production schedule.

  5. 05

    Prepare dispatch

    Check the finished packing and shipping details against the agreed order.

06 / QUALITY CHECKPOINTS

What to check before dispatch.

MEASUREMENT & FIT

Check what matters to the packed fit.

Review usable width, length and flap allowance against the agreed specification. An empty bag measurement should be supported by a packed sample where product fit is important.

  • Agree measurement points, units and tolerances.
  • Include seam allowances and any gusset in the drawing.
  • Record the approved sample and specification revision.
Define dimension checks
FUNCTIONAL CHECKS

Review the complete seal, not one feature.

Check the adhesive closure and converted seams against the intended use. Agree a suitable inspection or test method for the order, including how samples are conditioned and assessed.

  • Check release-liner removal and flap placement.
  • Inspect seam continuity and signs of opening or damage.
  • Agree test conditions and the required acceptance record.
Discuss seal inspection
VISUAL APPROVAL

Keep the finished pack aligned with the proof.

Compare finished print with the approved reference. Review colour, placement, registration and surface appearance, keeping functional areas such as labels and closures in the inspection plan.

  • Use the approved artwork revision and colour reference.
  • Check print placement against seams and flap position.
  • Define how visible defects and variations are assessed.
Set print acceptance criteria
COUNTING & DISPATCH

Make the shipment easy to receive and verify.

Finish the order brief with the packing details your receiving team needs. Clear bundle counts, carton marks and specification identification support checking and storage on arrival.

  • Agree quantity per bundle, carton and specification.
  • Confirm carton identification and packing-list information.
  • Review destination, handling needs and shipping arrangements.
Plan shipment packing
07 / BUYER’S GUIDE

Better information. A more useful quotation.

Mailing, postal or courier bags?

These names can describe overlapping dispatch uses. Specify the bag construction and intended shipment rather than relying on the name alone. If you need postal sacks or padded protection, state that separately.

Bulk orders & repeat supply

Include the quantity per size and artwork, expected reorder pattern and delivery destination. Minimum order quantities, pricing and lead times need confirmation against that specific brief.

Samples, proofs & prototypes

A stock sample helps assess an existing format. A digital proof checks artwork layout. A custom physical or pre-production sample checks the specified construction and print. Confirm which stage is included.

Choosing the right size

Measure the actual packed product, allowing for thickness and handling clearance. Keep the closure flap separate from usable bag length, and review fit with a sample before approving production.

BEFORE YOU ORDER

Your packaging questions, answered.

01What information is needed for a mailing bag quotation?

Start with the product you are packing, the usable bag width and length, closure flap, quantity per size and delivery destination. Add the material or thickness if known, plus print colours, artwork and any packing requirements. A photo of the packed item or an existing sample can help explain the application.

If the specification is still open, describe the product weight, dimensions and dispatch process. The quotation should identify the agreed specification, sample scope, setup charges and shipping basis so different options can be compared fairly.

02How do I choose the right mailing bag size?

Measure the product in the condition in which it will be shipped, including tissue, an inner bag, cushioning or a small box. Allow space for the product thickness and for your team to insert it without pulling the film tight. State usable width and usable length separately from the adhesive flap.

A flat bag measurement alone does not establish fit. Review a physically packed sample and check that the flap closes fully, the seams are not strained and the shipping label has a suitable clear area.

03Are mailing bags, postal bags and courier bags different products?

These terms often overlap when describing flexible outer bags for parcel dispatch. The name alone does not define material, dimensions, padding, closure or load suitability. A useful enquiry describes both the construction and the delivery application.

Clarify whether you mean individual self-sealing mailers, padded envelopes, reusable transport sacks or another format. Postal sacks for consolidated mail and bags used by delivery riders are different requirements and should be specified separately.

04Which material and thickness should I specify?

Choose around the packed product, weight, handling route and required appearance. Film thickness should be reviewed alongside material structure, opacity, seams and closure performance; a thicker film alone does not guarantee the right pack. State the thickness unit and whether you are referring to a single film wall.

Where no specification exists, share an existing bag or describe the performance you need. Compare proposed samples using the actual contents and agree the material, dimensions and acceptance criteria before placing the bulk order.

05Can I request custom colours, logo printing and different sizes?

Include each size, base colour and artwork version in your enquiry. For printed mailing bags, supply the design files, colour references, intended print sides and coverage, and identify any area that must remain clear for labels or sealing.

Feasibility, printing method, minimum quantity and setup charges depend on the final specification. Review a proof for placement and dimensions, then agree whether a physical printed sample is needed for colour, surface appearance and construction approval.

06What is the difference between a sample, proof and prototype?

A stock sample helps you assess an existing format or material. A digital proof checks artwork positioning and layout, but does not demonstrate physical bag strength, colour on the actual film or packed fit. A custom physical sample or pre-production sample can address the agreed construction and print requirements.

State what you want to approve and which features must match production. Confirm sample availability, cost, quantity, timing and shipping separately, and keep the approved sample or proof linked to the final specification.

07What is the minimum order quantity for wholesale mailers?

There is no single minimum that applies to every material, bag size and print design. Request the minimum and price for each specification, including whether quantities can be combined across sizes or artwork versions. Standard and custom printed formats may have different requirements.

For recurring supply, provide both the first order quantity and your expected reorder pattern. Compare unit prices together with setup charges, sample costs, carton quantities and delivery costs. The applicable minimum must be confirmed in the quotation.

08Can I request recycled-content packaging?

Include the requested recycled-content proportion and the evidence required by your purchasing team. Ask how the claim is defined and which documentation supports the proposed material. Colour, appearance and performance should be reviewed on a representative sample.

Recycled content and recyclability describe different things. Do not add disposal wording or environmental claims based only on a bag colour or appearance; confirm the material information and the collection guidance relevant to the destination before finalising printed messaging.

09What determines sampling, production and delivery lead times?

Timing depends on the confirmed specification, material availability, quantity, print setup and the sample approval process. Artwork changes or revisions after approval can affect the schedule, so keep one agreed version of the brief and record when approval is complete.

Ask for sampling time, production time and transit time separately. If the bags are needed for a launch or promotion, include the required arrival date and destination in the first enquiry. The workable schedule and shipping arrangement should be confirmed before the order is placed.

10Which quality checks should be agreed before production?

Define the characteristics that matter for your application: usable dimensions, film thickness, opacity, seam consistency, closure behaviour, print appearance and quantity. Link these to an approved specification or sample, with agreed measurement methods and tolerances where relevant.

If your purchasing team needs inspection records, third-party checks or supporting documents, request them before ordering. Confirm the scope and acceptance criteria for that order; do not assume a certificate, test result or inspection service is included without confirmation.

11Are self-sealing mailing bags suitable for fragile or heavy goods?

A flexible outer mailer provides no rigid structure by itself. Fragile products, sharp edges or concentrated loads may need a suitable inner box, cushioning or a different packaging format. Review the whole packed item and its handling route before deciding on a bag.

For heavier contents, specify the packed weight and discuss the film, seams and closure together. Evaluate a representative packed sample and agree any necessary handling or transit assessment rather than choosing only by bag dimensions or thickness.

12How are bulk orders packed, shipped and reordered?

Agree quantity per bundle and carton, identification for each size or artwork, and the packing-list details needed by your receiving team. Provide the delivery address or destination, receiving requirements and any requested shipment split so these can be assessed in the quotation.

For repeat orders, refer to the approved specification, artwork revision and previous sample reference. Highlight any change in material, dimensions, quantity or delivery destination. Confirm current availability, pricing and timing for each reorder rather than assuming the previous terms still apply.

LET’S BUILD YOUR PACKAGING BRIEF

Request a packaging quote.

Share your product, quantity and requirements. We’ll review the specification with you.