How to Choose the Right Polymailer Size: Reduce Shipping Cost & Packaging Waste
- Jan 31
- 2 min read
A Guide to Choosing the right Polymailers
Choosing the correct polymailer size may seem simple, but the right choice can save your business money, reduce packaging waste, and improve operational efficiency. This guide helps businesses select suitable polymailer sizes for products of all shapes and sizes, from small accessories to bulkier items.
1. Measure Your Product Accurately
Start by measuring your product’s length, width, and thickness in its final packed form. Include any protective layers like bubble wrap, tissue paper, or padding. Accurate measurements prevent overpacking, which increases shipping costs, or underpacking, which can damage items during transit.
2. Allowance for Thickness
Polymailers are flexible, but allow an extra 5–10 mm for comfortable packing. For padded or bundled items, include additional space to accommodate the bulk.
3. Overpacking vs Underpacking
Overpacking Risks: Oversized polymailers increase volumetric weight, leading to higher courier fees. They also consume more storage space and generate unnecessary waste.
Underpacking Risks: Too-small polymailers can damage products, trigger returns, or require repacking, which increases handling time.
4. Common Polymailer Sizes
Polymailer Size (cm) | Typical Product Uses | Notes |
15 x 25 | Small accessories (jewelry, stationery, small gadgets) | Minimal padding needed |
20 x 30 | Books, small apparel | Fits medium items snugly |
25 x 35 | T-shirts, light clothing | Standard e-commerce size |
30 x 40 | Bulk clothing packs, soft toys | Allows for light padding |
35 x 45 | Heavier clothing or multiple items | Check courier weight limits |
40 x 50 | Large or thick items | Use sparingly due to cost impact |
45 x 60 | Oversized or multiple-item shipments | Best for special orders |
CL Packaging Insight: Align your product dimensions closely with these sizes for optimal shipping efficiency.
5. Impact of Oversizing on Courier Fees
Courier charges are often calculated using volumetric weight, which considers package dimensions rather than actual weight. Choosing a larger polymailer than necessary increases shipping costs unnecessarily.
6. Storage Efficiency
Keeping multiple polymailer sizes in inventory ensures you always have the right option on hand. This avoids last-minute improvisation, keeps your warehouse organized, and reduces packaging waste.
CL Packaging Insight
Maintain a selection of 3–5 commonly used polymailer sizes that cover your product range. Periodically review your sales and packing patterns to optimize inventory, minimize waste, and reduce shipping costs.
Conclusion
Choosing the right polymailer size is key to reducing shipping costs, protecting products, and improving packing efficiency. By accurately measuring items, allowing for padding, and keeping multiple common sizes in inventory, businesses can minimize waste and avoid oversizing fees. Regularly reviewing packing practices ensures your operations stay cost-effective and environmentally responsible.
At CL Packaging, we help businesses across Singapore choose packaging that is strong, reliable, and thoughtfully made. The right mix of carton boxes, OPP tape, bubble wrap, and cling wrap brings structure to logistics — keeping your items protected and the process more predictable.
Explore our range of professional-grade packing materials for a steadier foundation.
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