When you’re shipping apparel or soft goods, packaging can make or break the delivery experience. Too bulky and you’re paying more in freight than you should. Too flimsy and you risk damaged stock, unhappy customers, and returns eating into your margins.
At eBPak, we work with thousands of Australian eCommerce brands shipping everything from apparel to accessories and many diverse products. For most apparel and soft goods, choosing the right mailer is simpler than you think, especially when we have the perfect packaging solutions for you.
So, let's look into how to choose the perfect option for your business.
Packing Smart: Apparel and Soft Goods
Clothing and soft goods have a few things in common:
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They’re flexible and compressible
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They don’t need rigid protection like electronics or glass
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They’re often shipped individually or in small bundles
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Shipping costs are heavily affected by weight and volume.
As a result, boxes are often overkill. Boxes add dead space, increase volumetric weight, and cost more to ship and store. Mailers on the other hand (such as our Mailing Satchel 05W 430mm x 545mm Poly Mailer White), conform to the product, reduce freight costs, and streamline fulfilment.
Best Overall Choice of Poly Mailers
For most garments, self-seal co-extruded poly mailers are the best all-round solution. At eBPak, we provide a vast variety of these types of poly mailers such as our self sealing poly bags that meet FBA (Fulfilment by Amazon) standards, which include pre-printed suffocation warning labels and resealable self adhesive seals, in a range of sizes.
Poly mailers are made from layered plastic film designed to be lightweight yet extremely tough. For apparel brands, they tick pretty much every box:
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Lightweight – keeps shipping costs down by taking up less space and weight, also known as DIM weight.
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Durable – resistant to tearing, punctures, and scuffs.
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Water-resistant – protects clothing from rain and spills.
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Flexible – moulds around garments to minimise wasted space.
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Cost-effective – affordable at scale.
It’s no surprise that poly mailer bags are the go-to choice for fashion and soft goods brands worldwide, and increasingly across poly mailer bags Australia wide.
Choosing the Right Microns
One of the most important decisions when choosing poly mailers is thickness. This is measured in microns, which refers to the thickness of the film. As a general guide:
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60–80 microns: ideal for most garments like t-shirts, activewear, dresses, underwear, and lightweight apparel
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80–100 microns: better for hoodies, denim, jackets, or multi-item orders
Thinner mailers reduce weight and cost, but going too thin can increase the risk of tearing, especially if parcels are tightly packed or handled roughly in transit. For most apparel brands, 70–80 microns is the sweet spot between strength and efficiency.
What to Look For in a Quality Poly Mailer
Not all poly mailers are created equal. Here are the features we recommend prioritising when shipping apparel and soft goods:
Strong Self-Seal Adhesive
A high-quality hot-melt adhesive ensures the mailer stays sealed during transit. This is critical for preventing accidental openings and reducing tampering risks.
Self-seal poly mailers also assist with faster packing times compared to using boxes or taped bags, which is especially helpful during peak periods.
Optional Tamper-Evidence
Some poly mailers include tamper-evident seals or irreversible adhesives. These add peace of mind, especially for higher-value items. For added protection, you can get poly mailers with bubble padding that also includes a tamper evident tight self-seal, like our best seller, fan-favourite Poly Bubble Mailer G1 01 160 x 230mm C5 Black.
Opaque or Matte Finish
An opaque or matte poly mailer provides privacy (no one can see what’s inside) and creates a more premium unboxing experience. Matte finishes also scuff less than glossy ones.
What Size of Poly Mailer is Best for Clothes?
One of the most common questions we hear is: what is the ideal poly mailer size for clothes?
The answer depends on the garment type and how many items you’re shipping, but here are some general guidelines:
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Small (250 x 325 mm) – single t-shirt, singlet, or lightweight garment
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Medium (300 x 400 mm) – folded shirts, dresses, leggings, or small bundles
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Large (350 x 500 mm or bigger) – hoodies, jackets, denim, or multi-item orders
The goal is a snug fit without overstuffing. Excess space adds volume, while overfilling can stress seams and adhesives. Always test with your actual folded garments before committing to a size.
Eco-Friendly Considerations
Sustainability is top of mind for many Australian brands, and rightly so. But are poly mailers biodegradable?
Although traditional poly mailers are not biodegradable, many are recyclable when made from LDPE (low-density polyethylene). These can often be recycled through soft plastics recycling programs, where available.
If biodegradability or compostability is a priority, there are alternative materials on the market. For example, at eBPak, we provide alternatives such as Compostable Courier Bags and Honeycomb Padded Mailers.
Eco-Friendly Alternative: Kraft Paper Mailers
Kraft paper mailers are a popular environmentally friendly alternative for apparel shipping. Even though they aren't as water resistant as poly mailers, They are recyclable, paper-based, and give a natural, premium feel.
If you choose to utilise kraft mailers, we recommend versions with tear strips and return strips to improve the customer experience and make returns easier; just in case the package accidentally rips if it comes in contact with anything sharp or wet.
When to Upgrade Your Packaging
While poly mailers work for most apparel and soft goods, there are times when an upgrade makes sense:
Use padded mailers when:
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Shipping delicate or premium soft goods.
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Sending items with embellishments, hardware, or accessories.
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You want added protection without moving to a box.
Use thicker poly bags with compression when:
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Shipping bulky soft goods like jumpers, towels, or bedding.
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You want to reduce volumetric shipping costs while still protecting product contents.
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You’re sending multi-item orders.
Where Can I Buy Poly Mailers?
When it comes to poly mailers, we recommend choosing a supplier that provides high quality packaging solutions but also understands eCommerce logistics, not just aesthetic packaging. This is where we come in. At eBPak, we have the best packaging solutions for you or your business.
We supply a wide range of poly mailer bags Australia businesses rely on every day. From standard self-seal mailers to eco-conscious alternatives and custom solutions, we help brands choose packaging that protects products, reduces shipping costs, and delivers a better customer experience.
Ready to Optimise Your Apparel Packaging?
Whether you’re scaling an online store or optimising your fulfilment process, at eBPak, we provide high-quality poly mailers designed for reliable, cost-effective shipping.
Browse our full range of poly mailers online, or order free samples to experience our premium materials firsthand. Shop with confidence knowing every purchase is backed by our money-back guarantee.
Feel free to chat with our friendly packaging experts today for personalised advice tailored to your packaging needs.