Bubble Mailers And Padded Satchels
Metallic foil and kraft bubble envelopes with bubble lining, self seal closure and fins on two or three sides
- Aluminium foil outer with bubble inside, or kraft paper outer
- PET and polyethylene construction
- Strong seams with fins on two or three sides
- Self seal closure with strong hot melt adhesive
Have a drawing or artwork? Send it straight to WhatsApp or email and we will check it against the die line.
Product Overview
What This Product Is
A bubble mailer is a poly or kraft envelope with a bubble film lining bonded inside it. It gives a hard item enough cushioning to survive a parcel network without the volume and dimensional weight of a box.
We produce metallic foil bubble mailers and kraft bubble mailers in PET and polyethylene, with an aluminium foil outer and bubble inside, colours from gold and silver through to black, blue, red, pink, purple, green and orange or custom. Seams are strong fins on two or three sides, closure is a hot melt self seal, and standard sizes cover the North American and European markets.
Key Benefits
Why Buyers Specify This Line
Cushioning Without A Box
Bubble lining protects hard goods while the pack still travels as a flexible envelope, which keeps dimensional weight down.
Strong Fin Seams
Fins on two or three sides rather than a single lap seam, so the pack resists tearing in the sorting network.
Metallic And Kraft Options
Aluminium foil outer for a premium unboxing look, kraft outer for recyclable and paper led positioning.
Ten Stock Colours Plus Custom
Gold, yellow, silver, black, blue, red, pink, purple, green and orange, or matched to your brand.
Prints, Stamps And Labels Directly
The outer surface accepts inks, stamps and labels.
Standard Sizes For Common Products
CD, DVD, portfolio, folder and large book sizes cover most media and small hard goods.
Application Scenarios
Where It Is Used
- Books, media and printed matter despatch
- Cosmetics, skincare and small glass items
- Phone accessories, cables and small electronics
- Jewellery and watch despatch
- Subscription boxes and influencer seeding kits
- Post office and small parcel handling
Who It Is For
Who Buys It
- Online sellers shipping small hard goods that need cushioning
- Brands that want a premium looking outer without a printed box
- Fulfilment operations standardising on a padded mailer range
- Distributors of protective packaging supplies
Problems It Solves
What It Fixes
Damage in the parcel network
Bubble lining absorbs the impacts a plain poly mailer transmits straight to the product.
Boxes that cost too much to ship
A padded envelope carries the same small hard goods at a fraction of the cube.
Seams splitting under load
Fins on two or three sides instead of a lap seam distribute the stress away from the edge.
Plain packaging that undersells the brand
Metallic foil outers in ten colours make the outer pack part of the unboxing.
Technical Features
Built In
- Aluminium foil outer with bubble inside, or kraft paper outer
- PET and polyethylene construction
- Strong seams with fins on two or three sides
- Self seal closure with strong hot melt adhesive
- Surface accepts inks, stamps and labels
- Master carton bulk packing or retail packing
Certifications
No certificate is listed against this specific line in our product data. Ask us on WhatsApp and we will confirm what documentation can be supplied for your market.
Certificates listed are those recorded against this production line. Copies for a specific shipment are supplied on request.
Specifications
Full Specification
| Description | Metallic bubble mailer, foil bubble envelope |
|---|---|
| Structure | Aluminium foil outer, bubble inside |
| Material | PET and polyethylene |
| Colour | Golden, yellow, silver, black, blue, red, pink, purple, green, orange, or custom |
| Surface | Easily accepts inks, stamps and labels |
| Strong Seams | Fins on two sides or three sides |
| Closure | Self seal, strong hot melt adhesive |
| Standard Size | Available for the North American and European market |
| Standard Package | Master carton, bulk packing, without inner pack |
| Special Size | Acceptable, can be custom made |
| Custom Printing | Acceptable, can be custom made |
| Application | Mailing, packing, small parcel, post office, stationery |
| Sales Package | Bulk packing or retail packing |
| Delivery Packing | Export carton or pallet packing |
US Standard Sizes
Inner size in inches.
| Item No. | Width | Length | Flap | Pcs Per Carton |
|---|---|---|---|---|
| AS-CD1 | 6 | 6.5 | 1.97 | 200 |
| AS-CD2 | 7 | 5.75 | 1.97 | 200 |
| AS-DVD | 6.5 | 10.5 | 1.97 | 100 |
| AS-PORTFOLIO | 12.75 | 9.25 | 1.97 | 100 |
| AS-FOLDER | 12.75 | 10.5 | 1.97 | 100 |
| AS-LARGE BOOK | 12 | 17 | 1.97 | 50 |
Materials
Material Options And What Each One Is For
Aluminium Foil Film
The metallic outer. Gives the colour, the sheen and a light moisture barrier.
PET And Polyethylene
The structural films. PET carries print and tear resistance, polyethylene carries the seal.
Bubble Film Lining
The cushioning layer bonded inside the envelope.
Kraft Paper Outer
Paper based alternative outer for recyclable positioning.
Hot Melt Adhesive Strip
The self seal closure under a release liner.
Manufacturing Process
How This Product Is Made
-
1
Film And Bubble Preparation
Outer film or kraft is prepared and bubble film is produced to gauge.
-
2
Printing
Custom artwork is printed on the outer surface.
-
3
Lamination
Outer and bubble lining are bonded together.
-
4
Bag Making
Envelopes are cut and fin sealed on two or three sides, and the flap is formed.
-
5
Adhesive Application
The hot melt self seal strip and release liner are applied.
-
6
Inspection
Seam strength, bubble bond, dimensions and print are checked.
-
7
Packing
Bulk into master cartons or retail packed, then export carton or pallet.
Quality Control
How This Line Is Checked
Quality control runs across three gates: incoming raw material, printed sheets and in process inspection, and finished product testing. The full published procedure is on the Trust Center page.
Incoming Material
- Ring crush and side crush test for paper and cardboard
- Moisture test for paper and cardboard
- Thickness and weight test for paper and cardboard
- Stiffness test for paper and cardboard
Finished Product
- Compressive strength test
- High and low temperature test
- Humidity and dryness test
- Transport vibration test
- Drop test
Customization Options
What Can Be Changed
- Custom envelope dimensions outside the standard chart
- Custom outer colour and printed artwork
- Kraft outer instead of metallic foil
- Fins on two or three sides
- Retail packing for resale
Send Us Your Drawing
We do not use web forms. Send the drawing, artwork or a photo of the product directly to WhatsApp or email and it reaches the engineer handling your project.
Comparison
Compared With Our Other Formats
| Bubble Mailer | Poly Mailer | Folding Paper Box | |
|---|---|---|---|
| Cushioning | Bubble lined | None | None unless an insert is added |
| Best contents | Books, media, small hard goods | Apparel and soft goods | Retail SKU presentation |
| Outer look | Metallic foil or kraft | White, grey, black or custom | Fully printed |
| Dimensional weight | Low | Lowest | Higher, fixed cube |
| Standard sizes | AS-CD1 to AS-LARGE BOOK | PM-1 to PM-7 | Made to die line |
Use Guide
Specifying It Well
- Measure the product and add about half an inch on width and length so the bubble can compress around it rather than being stretched flat.
- For anything with a corner or an edge, face the flat side against the bubble wall. Corners concentrate impact and are the usual failure point.
- Fins on three sides are worth specifying for heavier contents. Two sided fins are fine for media and flat goods.
- Metallic foil outers scuff. If the parcel goes through a rough network, a kraft outer holds appearance better.
- Do not overfill. A bubble mailer that will not lie flat under the flap will not seal reliably along the whole adhesive strip.
Related Industries
Industries Using This Product
Beauty And Cosmetics
Folding cartons, rigid gift sets and labels for skincare, colour and fragrance
Jewellery Bijou And Gifts
Rigid boxes, gift bags and protective mailers for high value small items
Perfume Candles And Home Decor
Gift boxes, cartons and carrier bags for fragrance, candle and interior brands
Consumer Electronics
Retail cartons, presentation boxes and durable component labels
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Buying Guide
Poly Mailer Size Guide For Online Retail
The PM-1 to PM-7 chart explained, how to measure a product for a mailer, and why the wrong size costs more than the bag itself.
Read Guide → 5 minBuying Guide
Bubble Mailer Selection Guide
AS-CD1 to AS-LARGE BOOK explained, two sided versus three sided fin seams, and when a metallic foil outer is the wrong choice.
Read Guide → 5 minRelated Work And Downloads
Our Work
See Bubble Mailers We Have Produced
Real production photography of this line, grouped by application, with the specification behind each group.
Download Center
Specification Sheet And Catalog PDF
Download the Bubble Mailers datasheet, the full company catalog and the quality control checklist as PDF.
FAQ
Bubble Mailers FAQ
What sizes do you make?
What is the mailer made from?
Which colours are available?
How strong are the seams?
Can they be printed?
How are they packed?
Question not answered here? Ask us on WhatsApp
Next Step
Get A Price For Bubble Mailers And Padded Satchels
Send the size, material, print colours and quantity and we will quote Bubble Mailers And Padded Satchels with a lead time and a sample plan. Drawings and artwork can go straight to WhatsApp.