Quick Take: Polybags vs. Boxes for Shipping

The fairly recent rise of eCommerce as a viable alternative to in-store shopping has created a wealth of new opportunities, but running an online storefront also creates some unique challenges. Figuring out how to safely and affordably ship all of those goods to your customers is just one of them, but it’s arguably one of the most important.

It doesn’t matter whether you take care of order fulfillment in-house or work with a third-party logistics company (3PL). If you’re still using nothing but cardboard boxes to ship products, the chances are good that it’s taking a hidden toll on the company’s budget.

Cardboard boxes are fantastic for shipping larger products, but they create unnecessary waste when used to ship smaller items. Shipping small products safely in cardboard boxes often requires extra packing materials to fill in the empty space so the items don’t get broken in transit, which creates an extra expense and a lot of unnecessary waste. If you’re already familiar with this problem, it’s time to consider adding polybags to the company’s shipping lineup.

What Are Polybags?

Polybags, also known as poly mailers, are used extensively by experts in eCommerce shipping. These lightweight yet sturdy plastic bags come in multiple sizes and styles, making it easy to find the right one to fit your shipping needs.

Types of Polybags

If you want to use polybags to ship items, it’s important to learn about the different types available. Each type of poly mailer is designed to fulfill a specific purpose and set of applications, so choosing the right one is the key to optimizing your packaging and shipping expenses. The most common types of polybags are:

Lay-Flat Polybags

Lay-flat polybags are available in many sizes and thicknesses. They feature a single opening that can be sealed using tape, ties, staples, or heat, depending on the material. Thicknesses range from 1 mil to 6 mils or higher.

Bubble-Lined Polybags

Bubble-lined polybags are designed for small items that need a little extra protection during shipping and handling. They combine a plastic outer shell with an inner lining of bubble wrap to create a ready-to-mail packaging solution.

Resealable Polybags

Resealable polybags can be either lay-flat or bubble-lined. Both options can be opened and resealed, making it easier and more affordable to facilitate returns when necessary.

Anti-Static Polybags

As the name implies, anti-static polybags are resistant to static, making them ideal for shipping sensitive electronic equipment.

Polypropylene Polybags

Most poly mailers are opaque, with polypropylene polybags being the exception. They are made from high-clarity, fully transparent plastic and can be used to showcase items being shipped, usually perishable foods, while simultaneously keeping them safe from moisture.

Expansion Polybags

Expansion polybags are made from heavy-duty polyethylene. They’re designed primarily to protect goods from moisture but are also puncture, tamper, and tear-resistant. The padded bottoms in expansion polybags also allow them to be used to ship thicker items.

Polybags vs. Cardboard Boxes: How to Choose

Now that you know what types of polybags are available, it’s time to address a second essential question: how to choose between polybags and cardboard boxes. When choosing a packaging solution, consider the following factors.

Product Size

Like cardboard boxes, polybags come in different shapes and sizes. However, they’re only suitable for shipping smaller goods, unlike cardboard boxes. Large items always need to be shipped in boxes.

Customization Requirements

There’s only so much one can do to customize the size and shape of a cardboard box. With poly mailers, you can order custom bags that match a product’s dimensions precisely, further reducing the need for extra packaging.

Branding & Customer Experience

Both polybags and boxes can be customized, but they offer different branding opportunities. Poly mailers can be printed with logos, patterns, and brand colors, allowing businesses to create a recognizable look. However, boxes provide more surface area for branding and can be enhanced with custom inserts, tissue paper, and stickers, making for a more premium unboxing experience.

Security is another factor to consider. Some polybags come with tamper-evident seals, but boxes are generally more secure since they can be reinforced with packing tape or even tamper-proof stickers.

Are Polybags Cheaper than Boxes?

There’s a good reason that many eCommerce business owners use polybags instead of cardboard boxes, and it’s that they are lightweight and cost less to mail. In many cases, poly mailers are smaller than boxes, which can make a difference if the shipping company charges based on how much room packages take up in the trucks.

Company Image

Today’s consumers are very conscious of the impact their shopping choices have on the environment, so it’s common for companies to adopt green practices to bolster their images. Of course, plenty of business owners genuinely want to create less of an ecological impact. Either way, polybags are often made from recyclable and/or biodegradable materials, making them an eco-friendly option.

Cost Efficiency

Cost is one of the biggest factors when choosing between polybags and boxes. The material and production costs for polybags are generally lower than those for cardboard boxes, making them an attractive option for businesses looking to save on packaging expenses.

Shipping costs can also vary depending on the choice of packaging. Since poly mailers are lightweight and take up less space, they often result in lower shipping fees, especially when carriers calculate costs based on dimensional weight. Additionally, because polybags are flexible, they can be stored more efficiently in warehouses, freeing up valuable space compared to bulkier cardboard boxes.

Protection & Durability

If an item requires significant protection, a cardboard box is the better option. Boxes provide more resistance to impact and compression, which is crucial for fragile, perishable, or high-value items. On the other hand, polybags offer little structural protection and are best suited for soft goods or non-breakable products.

For extra protection, businesses can use internal packaging materials like bubble wrap, packing peanuts, or air pillows inside boxes. Polybags also come in padded varieties, but they may not be enough for particularly delicate shipments.

Sustainability & Environmental Impact

Today’s consumers are very conscious of the impact their shopping choices have on the environment, so it’s common for companies to adopt green practices to bolster their image. Of course, plenty of business owners genuinely want to create less of an ecological impact. Either way, polybags are often made from recyclable and/or biodegradable materials, making them an eco-friendly option.

Cardboard boxes, however, are typically more sustainable. They are widely recyclable and often made from post-consumer materials. Some eco-friendly alternatives, such as compostable mailers or recycled-content polybags, also provide a greener choice for businesses looking to reduce their carbon footprint.

Shipping Carrier Requirements & Regulations

Different carriers have different rules when it comes to packaging. Some shipping methods require more protective packaging, which means polybags may not always be an option. Carriers also determine shipping costs based on size and weight, with dimensional weight pricing playing a major role. Because poly mailers take up less space, they can help reduce shipping fees, whereas boxes may increase costs if they exceed certain size limits.

Additionally, some carriers restrict polybag use for certain types of shipments. Businesses should always check with their shipping providers to ensure compliance with packaging guidelines.

Items Commonly Shipped in Boxes vs. Polybags

Still unsure whether polybags will be a good fit for your eCommerce business? Generally, you should never use them to ship fragile items that could be crushed unless they are already in sturdy packages. For those, stick with cardboard boxes. If an item will be OK if something heavy gets placed on top of it, it’s usually fine to use a poly mailer. Common examples of items shipped in polybags include:

Books and Printed Media

Books and other printed media can always be mailed in polybags. If you’re worried about rips or dents, go for a bubble-lined polybag. Otherwise, a lay-flat poly mailer will do.

Cloth and Fabric-Based Products

Any item made of cloth or fabric will be a good candidate for shipping via polybag. This category of products includes things like yarn, face masks, bedding, sheet sets, fabric swaths, and most apparel.

Items Already in Sturdy Packaging

Small items that already come in sturdy packaging can usually be mailed using polybags. Examples include smaller board games, packaged cosmetics, vitamins and supplements, and some kinds of electronic accessories.

When to Use Polybags vs. Boxes

Choosing the right packaging depends on the type of product being shipped. While both polybags and cardboard boxes offer distinct advantages, certain shipping scenarios make one option more suitable than the other.

Best-Case Scenarios for Polybags

Polybags are ideal for shipping lightweight, non-fragile items that do not require rigid protection. Some of the best-use cases include:

• Apparel and Textiles – T-shirts, jeans, socks, and other clothing items ship well in poly mailers since they are soft and durable.
• Bags and Accessories – Items like tote bags, small backpacks, and scarves fit securely in poly mailers without the need for additional padding.
• Books and Magazines – While fragile books may need extra protection, most paper-based products can be shipped in polybags, especially if a padded version is used.
• Beauty and Personal Care Products – Non-fragile beauty products, such as makeup sponges, hair accessories, or lightweight cosmetic bags, are often suitable for poly mailers.
• Small Electronics Accessories – Cables, chargers, and phone cases can often be shipped in polybags, provided they are well-protected inside.

Best-Case Scenarios for Boxes

For heavier, fragile, or high-value products, cardboard boxes provide the necessary protection against impact, compression, and potential damage. Boxes work best for:

• Fragile Items – Glassware, ceramics, and delicate electronics require the structural integrity of a box to prevent breakage.
• Heavy Products – Items like books, canned goods, or weights are better suited for boxes that can handle extra weight without tearing.
• High-Value Goods – Jewelry, premium electronics, and collectibles benefit from the security of a rigid box, which reduces the risk of theft or tampering.
• Multiproduct Orders – When shipping multiple items together, a box helps keep everything organized and prevents movement that could cause damage.
• Oddly Shaped or Bulky Items – Some products, like home appliances or large toys, require a box to accommodate their unique dimensions and keep them secure.

Hybrid Solutions: Box-in-Bag Shipping and Padded Mailers

In some cases, a combination of both packaging types can offer the best of both worlds. Hybrid solutions include:

• Box-in-Bag Shipping – A small, lightweight box placed inside a polybag reduces packaging bulk while maintaining protection. This method is useful for products that need some rigidity but don’t require a large box.
• Padded Mailers – Bubble-lined poly mailers provide additional cushioning, making them a great alternative for small, semi-fragile items like DVDs, phone accessories, or delicate clothing with embellishments.
• Mailer Boxes – These are compact, sturdy boxes designed for small products but can still be lightweight enough to avoid high shipping costs.

By understanding the strengths and limitations of each packaging type, businesses can optimize their shipping strategy, balancing cost, protection, and customer experience.

The Easiest Way to Choose a Shipping Solution

The easiest way to choose between cardboard boxes and polybags is to entrust this decision to a reputable and experienced third-party logistics company (3PL). We have enough experience working with eCommerce merchants to know that there’s no one right solution for every shipping scenario. Instead, we’ll choose the perfect packaging for each item based on your company’s needs.