Wholesale Bubble Mailers: Size Chart by Product and Poly vs Kraft Compared (2026)

Choosing wholesale bubble mailers comes down to two decisions: the size and the outer material. Pick a size that is too small and your packers lose time forcing items in or switching formats. Pick one that is too large and you pay more per parcel in material, storage and often carrier charges. This guide gives you a size-by-product chart, a direct comparison of poly bubble mailers and kraft bubble mailers, and a checklist for businesses that buy in volume. Dimensions are shown in both inches and millimetres because suppliers and carriers around the world use different units. Where rules or availability differ between countries, we say so.

Key takeaways

• Bubble mailer sizes follow a numbering system (#000 to #7) that is common across the industry, but exact dimensions can differ slightly between manufacturers. Always check the product page.
• The usable space is smaller than the stated inner size once you allow for the seal flap and a little cushioning room.
• Poly bubble mailers resist water and tearing best. Kraft bubble mailers give a paper look and a stiffer feel, but they cope less well with wet conditions.
• Bubble mailers suit soft, flat or lightly fragile goods. Rigid, heavy or breakable items usually need a box.
• Measure your packed product, not the product alone, and match it to the inner dimensions in the chart below.
• At Pack Merchants every product has its own minimum order quantity worth at least $500, payment is in advance, and freight is quoted separately.

What wholesale bubble mailers are and who they suit

Wholesale bubble mailers are cushioned envelopes bought in large quantities, usually by the carton or pallet, rather than in small packs. They are also sold as padded mailers or padded envelopes, and buyers searching for padded envelopes wholesale are generally looking for the same product. Ecommerce brands, retailers, print-on-demand businesses and fulfilment warehouses use them because they are light, quick to pack and cheaper to ship than boxes.

How a bubble mailer is built

Most bubble mailers have three parts: an outer skin, an inner layer of air-filled bubble film, and a closure, typically a peel-and-seal adhesive strip. The outer skin is either a polyethylene film (poly) or kraft paper. The cushioning is almost always a plastic bubble layer, although paper-based padding exists in some ranges. The outer skin carries the print, resists abrasion in sorting machines and sets how the mailer behaves in rain.

Where bubble mailers fit and where they do not

They work well for small accessories, cosmetics, jewellery in a retail box, phone cases, books, documents, apparel samples and light electronics accessories. They are a poor choice for glass, ceramics, heavy metal parts or anything with sharp edges that can pierce the film. For those, see our guide to ecommerce mailer boxes compared with shipping boxes and mailers.

Bubble mailer size chart: dimensions in inches and millimetres

The chart below uses the numbering most buyers and carriers recognise. Dimensions are the inner width by length. Treat them as a guide: manufacturers round differently, and the product page for the exact mailer you plan to buy is the final reference.

Size code	Inner size (in)	Inner size (mm)	Typical contents
#000	4 x 8	102 x 203	Small jewellery box, lip balm, SD cards, small accessories
#00	5 x 10	127 x 254	Earbuds, small cosmetics, slim phone case
#0	6 x 10	152 x 254	Phone cases, small books, trading cards in a rigid holder
#1	7.25 x 12	184 x 305	Paperbacks, DVD cases, small apparel items
#2	8.5 x 12	216 x 305	Cosmetic sets, thin hardbacks, folded scarves
#3	8.5 x 14.5	216 x 368	Slim tablets in a sleeve, long accessories, flat documents
#4	9.5 x 14.5	241 x 368	A4 or Letter documents, magazines, thin folded garments
#5	10.5 x 16	267 x 406	Folded T-shirts, larger books, small bundles
#6	12.5 x 19	318 x 483	Folded hoodies or jackets (light fabrics), multi-item orders
#7	14.25 x 20	362 x 508	Bulky soft goods, larger multi-item orders

How the size numbers work

The # numbers are a convention, not a legal standard. A #0 from one maker is normally 6 x 10 in (152 x 254 mm), but another may be a few millimetres off. Some suppliers list only the dimensions, others list only the number. Use the dimensions whenever both are available.

Inner size versus usable size

The seal flap and side seams use up space. As a working rule, allow at least 0.5 in (12 mm) of spare width and 1.5 in (40 mm) of spare length beyond your packed item. Thick items need more width because the mailer has to bulge around them. If a supplier gives outer dimensions, remember that these are larger than the space you can use.

Where bubble mailers 6x10 fit

Bubble mailers 6x10 (#0) are one of the most searched sizes because they suit a wide range of small goods: phone cases, small cosmetics, accessories and slim paperbacks. They are a sensible first size to evaluate if most of your catalogue is small and light, but only your own measurements can confirm the fit.

Which size to buy for each product

Start from the packed product, meaning the item inside its own retail box, sleeve or tissue. Measure the longest side, the widest side and the thickness, then compare against the inner dimensions above.

Small, light items

For jewellery boxes, lip products, small electronics accessories and phone cases, the #000 to #0 range usually works. A snug fit matters here: if the item slides around, the cushioning cannot do its job, and a loose item can burst through a seam under pressure. If a product is both small and valuable, consider a tamper-evident closure and a plain outer so the contents are not advertised.

Books, documents and soft goods

Books and documents tend to fail at the corners, so choose a size with a little margin instead of a tight fit. Folded apparel is more forgiving because fabric compresses, but thick knitwear can push a mailer over its weight and thickness limits. The table below gives a starting point.

Product	Approx. packed size	Suggested starting size	Note
Phone case in sleeve	6 x 3.5 in (150 x 90 mm)	#00 or #0	Check thickness of any retail box
Mass-market paperback	7 x 4.25 in (178 x 108 mm)	#0 or #1	Allow room for corners
Trade paperback	8.5 x 5.5 in (216 x 140 mm)	#1 or #2	Choose #2 if the book is thick
A4 or US Letter documents	11.7 x 8.3 in / 11 x 8.5 in	#4	Add card backing to prevent bending
Folded T-shirt (light cotton)	Approx. 12 x 9 in (305 x 230 mm)	#4 or #5	Varies with fabric weight and fold
Folded hoodie (light fabric)	Approx. 14 x 11 in (355 x 280 mm)	#6 or #7	Poly is often easier for soft goods

These figures are estimates for planning. Product sizes vary by brand, so always measure your own packed items before you commit to a size across a full order. If your goods are soft and not fragile, a plain poly mailer may do the job for less; our poly mailer size chart and fit guide covers that format.

Poly bubble mailers vs kraft bubble mailers

This is the choice that changes how your parcel looks, how it behaves in the rain, and what you can honestly say about its environmental impact. Neither is better in every case.

Factor	Poly bubble mailers	Kraft bubble mailers
Outer material	Polyethylene film	Kraft paper
Water resistance	High; the film sheds rain	Lower; paper can soften or stain when wet
Tear and puncture resistance	Strong stretch and tear resistance	Can tear at creases or when punctured
Rigidity	Flexible, conforms to the item	Stiffer, holds a flat shape
Appearance	Smooth, good for bold printed branding	Natural, earthy look
Weight	Usually lighter	Often slightly heavier
Typical lining	Plastic bubble layer	Usually plastic bubble layer; check for paper-based padding
Best for	Wet climates, long transit, soft goods	Brands wanting a paper look, dry or short routes

Protection and durability

Poly bubble mailers handle rough sorting better because the film stretches before it tears. Kraft bubble mailers have a firmer feel, which some buyers prefer for flat items like documents, but a sharp corner can cut paper more easily. For long international routes with many handling points, poly is usually the safer default.

Moisture and weather

If your customers live in humid or rainy regions, or your parcels cross climate zones, the moisture behaviour of the outer skin matters. Paper takes up water, loses strength and can let the seal strip fail. Poly protects the contents from a wet doorstep. Neither format is a substitute for waterproof inner packing when the contents are moisture-sensitive.

Look, branding and printing

Poly gives a smooth surface suited to full-colour or one-colour print. Kraft gives a natural base that suits stamps, stickers and simple one-colour branding. If you need custom packaging, quotes are made per order.

Recycling and sustainability claims

A paper outer does not automatically make a mailer recyclable. If the lining is plastic bubble film, many municipal paper recycling systems will not accept it as is, and rules differ widely between countries and even between cities. Ask the supplier exactly what the lining is made from, and avoid claims on your own website that the specification does not support. For a deeper look at paper formats, read our guide on when kraft paper mailers work and when poly wins.

Padded envelopes wholesale: how they compare with other formats

Bubble mailers sit between plain mailers and boxes. Before you commit to a bulk order, check whether a different format would suit part of your range better.

Bubble mailer or poly mailer

A plain poly mailer is thinner, cheaper per parcel in most cases, and takes up very little warehouse space. It suits clothing, soft goods and items that need no cushioning. A bubble mailer costs more but protects against knocks. If you ship both soft and semi-fragile items, many businesses hold two formats. Our poly mailer vs bubble mailer decision table sets out that choice in detail.

Bubble mailer or mailer box

Mailer boxes keep their shape under stacking pressure and are better for rigid goods, gift items and products that must not bend. They are bulkier to store and heavier to ship. If a product gets damaged in a bubble mailer even with the right size, the answer is probably a box rather than a thicker mailer. For other protective options, Pack Merchants also supplies honeycomb paper wrap and corrugated shipping boxes, and the choice depends on the item, the route and how much storage space you have.

What to check before you buy bulk bubble mailers

Buying in volume means one wrong specification is repeated thousands of times. Spend an hour on the checks below before you place an order. The same points are explained further in our bulk bubble mailers guide to order sizes and what to check.

Specification checklist

• Exact inner dimensions in both inches and millimetres, not just the size number.
• Outer material: poly film or kraft paper, and the film thickness or paper weight where stated.
• Cushioning type: bubble layer material and whether it is bonded to the outer skin.
• Closure: peel-and-seal strip quality, flap depth and whether the strip works in cold or humid conditions.
• Packing format: units per carton, cartons per pallet and carton dimensions, which drive storage and freight.
• Carrier limits: maximum weight and thickness for your chosen postal or courier service, which differ by country and carrier.

Measuring your products without samples

We do not offer samples, so work from dimensions instead. Pack a real product with its retail box, measure it with a ruler or callipers, and mark out the inner size on card or a sheet of paper. Fold the card to mimic the flap and test whether the product sits comfortably. This takes minutes and reveals most sizing errors. For rigid items, test with the heaviest product in your range, not the lightest.

Ordering, payment and freight for bulk orders

Wholesale terms are different from retail, so plan your first order around them.

Minimums, payment and freight

At Pack Merchants, every product has its own minimum order quantity worth at least $500, and the exact quantity is shown on the product page. All prices are in US dollars. Payment is made in advance by bank transfer or USDT, a US-dollar stablecoin. USDT is the only cryptocurrency we accept, and we do not offer credit or Net payment terms. Freight is always quoted separately because it depends on your destination, the weight and the shipping method.

Working out cost per shipment

Do not compare mailers by unit price alone. Add the unit price, your share of freight per mailer, the storage cost per pallet position, and the carrier cost difference between a smaller and larger parcel. Then add the cost of damage and replacements. A mailer that costs slightly more but removes a damage rate is cheaper in total. A size that is a notch smaller can also move a parcel into a lower postal band in some countries, but carrier rules vary, so check your own carrier's tariff.

If you stock several sizes, start with the two or three that cover most of your orders, and review your sales data before adding more. Fewer sizes means simpler picking and less dead stock.

Conclusion

The right wholesale bubble mailers depend on measuring your packed product against the inner dimensions, then choosing between a poly outer for moisture and tear resistance and a kraft outer for a paper look. Bubble mailers suit soft and lightly fragile items, while rigid or heavy goods belong in boxes. To see current sizes and the minimum order quantity for each product, visit the bubble mailers product page on Pack Merchants, or use the quote request page to ask about custom packaging and freight for your order.

Frequently asked questions

What is the most common bubble mailer size?

There is no single standard, but sizes such as #0 (6 x 10 in, 152 x 254 mm), #2 (8.5 x 12 in) and #4 (9.5 x 14.5 in) appear on most size charts. The right one depends on your packed product. Measure the item in its retail packaging and compare it with the inner dimensions.

Are kraft bubble mailers recyclable?

Not always. Many kraft bubble mailers have a plastic bubble lining, which can stop them being accepted in paper recycling. Rules differ between countries and cities, so ask the supplier what the lining is made from and check your local collection rules before making any recycling claims.

Are poly bubble mailers waterproof?

Poly bubble mailers resist rain and splashes much better than paper-based ones, because the outer film does not absorb water. They are water-resistant rather than guaranteed waterproof, since seams and the seal strip can still let moisture in under prolonged soaking.

Do you offer samples of bubble mailers?

No. We do not offer samples. Check the inner dimensions on the product page, then mock up the size from card using your own packed product to confirm the fit before ordering.

What is the minimum order for wholesale bubble mailers?

Each product has its own minimum order quantity, worth at least $500. The exact quantity is listed on that product page, so check it for the size and material you want.

How do I pay for a bulk order?

Payment is made in advance by bank transfer or USDT, a US-dollar stablecoin. USDT is the only cryptocurrency we accept, and we do not offer credit or Net payment terms. All prices are in US dollars.

Is freight included in the price?

No. Freight is always quoted separately, as it depends on your destination, the weight of the order and the shipping method. Request a quote to get freight for your location.

Are padded envelopes the same as bubble mailers?

In most cases, yes. Padded envelope, padded mailer and bubble mailer are different names for an envelope with cushioning built in. Some padded envelopes use paper-based padding instead of bubble film, so check the specification.