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Mailer Packaging Market Report


Mailer Packaging Market by Product (Cushioned Mailers, Non-cushioned Mailers), Insulation (Insulated and Non-insulated), Material (Plastic, Paper, and Foil), End-Use (E-commerce, Shipping & Logistics, and Manufacturing & Warehousing) and Region (North America, Europe, Asia-Pacific, and LAMEA): Opportunity Analysis and Industry Forecast, 2023-2032


Pages: 370

Oct 2023

Mailer Packaging Overview

mailer packaging market is an industry dedicated to the manufacturing and distribution of mailer packaging solutions. Also known as shipping envelopes or poly mailers, mailer packaging is designed to safeguard and ship items using postal or courier services. Its lightweight nature and economic benefits reduce shipping costs and environmental impact.

The market is highly competitive, with numerous companies focusing on research and development to enhance the durability, sustainability, and design of their products. Advancements in printing technology allow for customization, enabling businesses to incorporate branding and promotional messages on their packaging.

Global Mailer Packaging Market Analysis

The global mailer packaging market size was $20.46 billion in 2022 and is predicted to grow with a CAGR of 15.0%, by generating a revenue of $74.96 billion by 2032.

COVID-19 Impact on Global Mailer Packaging Market

The COVID-19 pandemic has had a significant effect on the mailer packaging market. The surge in e-commerce due to lockdowns and social separating measures has fueled the demand for mailer bundling materials to dispatch items to clients.  Besides, buyer conduct, and inclinations have changed, with a more prominent accentuation on the bundling that guarantees item security and cleanliness. This has expanded the demand for tamper-evident bundling and eco-friendly alternatives. However, the pandemic has disturbed worldwide supply chains, causing deficiencies, delays, and calculated challenges for producers and providers. Despite these challenges, there has been a developing accentuation on the e-commerce bundling involvement, driving imaginative and outwardly engaging plans. Maintainability contemplations have remained a need, with expanded need for recyclable and biodegradable bundling materials.

Growing E-commerce Industry to Drive the Market Growth

The rapid growth of the e-commerce industry is a major driver of the mailer packaging market. With the increase in online purchases, there is an increasing demand for protective packaging, such as envelopes and boxes, to safely deliver goods. Secondly, the need for product protection during transportation is very important. To ensure that the product reaches the customer in good condition and the shipping packaging is padded and impact resistant. In addition, there are cost benefits as the lightweight packaging for shipping minimizes material usage, reduces the need for additional protective fillers, and reduces shipping costs. Additionally, sustainability is becoming more and more important, demanding eco-friendly shipping packaging made from recyclable or biodegradable materials. The ability to customize and brand shipping packages is another driver that enables businesses to build brand awareness and create memorable unboxing experiences. Additionally, shipping packages with features such as tape and tear-off perforations provide convenience and ease of use for businesses and customers. The globalization of e-commerce and cross-border trade has increased the need for shipping packaging materials that can withstand international transportation and meet various regulations.

Environmental Concerns to Restrain the Market Growth  

The mailer packaging market faces several impeding factors. One of the biggest challenges is growing environmental concerns and regulations around plastic waste and sustainability. Shipping packaging materials, such as plastic and bubble wrap, are usually troublesome or incomprehensible to reuse, driving to natural issues. In addition, the rise of online shopping is increasing the number of returns and trades, driving an upsurge in bundling waste. Furthermore, the rising need for feasible bundling choices, such as moderate and recyclable bundling, seems to affect the demand for conventional shipping bundling. Cost consideration is another factor limiting the market growth. Shipping packaging can be expensive compared to other options, especially for large items. Fragile and sensitive items may require more robust packaging solutions, limiting the use of shipping packaging. In addition, shipping packages have size and weight restrictions, so they are not suitable for larger or heavier items. Security and tampering risks are also an issue, as shipping packaging is more vulnerable to tampering and theft.

Expansion of E-commerce to Drive Excellent Opportunities

The mailer packaging market is brimming with opportunities for growth and advancement. The surge in e-commerce has fueled the demand for efficient and cost-effective packaging solutions, making mailer packaging an ideal choice for shipping small to medium-sized products due to its lightweight and compact nature. Moreover, the increasing emphasis on sustainability presents a promising avenue for mailer packaging companies, as eco-friendly alternatives made from recycled materials or biodegradable options gain traction. Customization and branding are also key drivers, allowing businesses to create memorable unboxing experiences and foster customer loyalty. Technological advancements have opened doors for innovative features such as tear-resistant, waterproof, and tamper-evident materials, as well as interactive elements like QR codes and NFC tags. Furthermore, the global expansion of e-commerce provides opportunities for mailer packaging that complies with international shipping standards. The rise of subscription box services and the need for efficient return and reverse logistics solutions further contribute to the growth of the mailer packaging market. Staying updated on evolving trends and developments will be crucial to capitalize on these opportunities in this dynamic industry.

Global Mailer Packaging Market Share, by Product, 2022

The cushioned mailers sub-segment accounted for the highest market share in 2022. Cushioned mailers, also known as padded mailers or bubble mailers, have dominated the mailer packaging market due to several key factors. Firstly, they offer superior protection for delicate items during shipping, thanks to the internal layer of bubble wrap or foam padding that absorbs shock and minimizes the risk of damage. Secondly, cushioned mailers are lightweight, reducing shipping costs and contributing to eco-friendly shipping practices. Their cost-effectiveness is another advantage, as they are cheaper to manufacture and require less storage space than rigid boxes. Furthermore, cushioned mailers come in various sizes, making them versatile for different products, and can be customized with branding, enhancing the unboxing experience. Their ease of use and quick assembly add to their convenience, particularly for e-commerce businesses. Lastly, cushioned mailers have responded to sustainability concerns by being made from recycled and recyclable materials. Overall, the combination of protection, cost-effectiveness, versatility, convenience, and environmental considerations has propelled cushioned mailers to dominate the mailer packaging market.

Global Mailer Packaging Market Share, by Insulation, 2022

The insulated sub-segment accounted for the highest market share in 2022. Insulation has had a significant impact on the mailer packaging market, particularly in industries that require the shipment of temperature-sensitive or perishable items. In sectors like food and pharmaceuticals, where online delivery is increasingly popular, insulation has become dominant. Insulated mailer packaging, which incorporates materials like foam, bubble wrap, or insulated liners, is designed to maintain the desired temperature range during transit. These materials are often combined with other components such as corrugated cardboard to create sturdy and protective packages. By using insulated mailers, businesses can ship perishable goods over longer distances without compromising their quality, expanding their reach and reducing the need for expensive refrigerated shipping. While factors like cost, sustainability, and product protection also influence packaging choices, insulation has undoubtedly made its mark in the mailer packaging market.

Global Mailer Packaging Market Share, by Material, 2022

The paper sub-segment accounted for the highest market share in 2022. Paper-based packaging dominates the mailer packaging market for a variety of reasons. First, paper is considered a feasible and ecologically friendly option compared to materials such as plastic. Its biodegradable, recyclable, and renewable nature makes it exceptionally alluring to both businesses and customers who prefer environmentally friendly choices. Furthermore, growing awareness of environmental issues has increased the demand for sustainable packaging solutions. Many companies are actively seeking alternatives to traditional plastic packaging, and paper-based shipping packaging is gaining popularity. Additionally, paper's versatility allows it to be easily shaped, folded, glued and printed, offering opportunities for customization and branding. Its lightweight nature reduces shipping costs and CO2 emissions, providing a better user experience. In addition, using paper-based shipping packages can improve your brand image and attract green customers. Increasing restrictions on plastic packaging by governments and regulators are also encouraging the use of paper alternatives. Finally, continuous innovation and advancement have increased the strength, durability, and water resistance of paper-based packaging, making it a viable option for a wide range of products.

Global Mailer Packaging Market Share, by End-Use, 2022

The e-commerce sub-segment accounted for the highest market share in 2022. E-commerce has significantly impacted the mailer packaging market, establishing its dominance in recent years. The exponential growth of online shopping has resulted in a substantial increase in package shipments, driving the demand for mailer packaging solutions. E-commerce businesses recognize the importance of creating a memorable unboxing experience and invest in customized mailer packaging that reflects their brand identity, fostering brand recognition and customer loyalty. Furthermore, mailer packaging offers cost-effectiveness and lightweight properties, reducing shipping expenses for e-commerce companies. Made from materials such as paperboard or plastic, mailer bundling is more reasonable to create, and transport compared to conventional layered boxes.

Global Mailer Packaging Market Share, by Region, 2022

The Asia-Pacific mailer packaging market generated the highest revenue in 2022. Asia Pacific has dominated the mailer packaging market due to several factors. Its status as a major manufacturing hub led by countries such as China and India have resulted in lower production costs. The booming e-commerce industry is driving the demand for efficient packaging solutions, benefiting manufacturers in the Asia-Pacific region. Population growth, urbanization and a rising middle class have further strengthened this dominance. Technological advances, infrastructure development, and government support also play an important role in the growth of the region's market. While other regions still hold market share, Asia Pacific's strengths in manufacturing, e-commerce, and favorable market conditions have led to its dominance in the mailer packaging market.

Competitive Scenario in the Global Mailer Packaging Market

Investment and merger are common strategies followed by major market players. Some of the leading global mailer packaging market players are Pregis LLC, 3M Company, Sealed Air Corporation, ProAmpac LLC, Georgia-Pacific LLC, Intertape Polymer Group Inc, Crown Packaging Corp., Mondi, Abriso Jiffy, Henkel Corporation.



Historical Market Estimations


Base Year for Market Estimation


Forecast Timeline for Market Projection


Geographical Scope

North America, Europe, Asia-Pacific, and LAMEA

Segmentation by Product

  • Cushioned Mailers
  • Non-cushioned Mailers

Segmentation by Insulation

  • Insulated
  • Non-insulated


Segmentation by Material



  • Plastic
  • Paper
  • Foil

Segmentation by End-Use


  • E-commerce
  • Shipping & Logistics
  • Manufacturing & Warehousing

Key Companies Profiled

  • Company
  • Pregis LLC
  • 3M Company
  • Sealed Air Corporation
  • ProAmpac LLC
  • Georgia-Pacific LLC
  • Intertape Polymer Group Inc
  • Crown Packaging Corp.
  • Mondi
  • Abriso Jiffy
  • Henkel Corporation


Frequently Asked Questions

A. The size of the global mailer packaging market was over $20.46 billion in 2022 and is projected to reach $74.96 billion by 2032.

A. Georgia-Pacific LLC and Intertape Polymer Group Inc. are some of the key players in the global mailer packaging market.

A. The Asia-Pacific region possesses great investment opportunities for investors to witness the most promising growth in the future.

A. Agreement and merger are the two key strategies opted by the operating companies in this market.

A. Georgia-Pacific LLC, Intertape Polymer Group Inc, Crown Packaging Corp., Mondi, Abriso Jiffy, and Henkel Corporation are the companies investing more on R&D activities for developing new products and technologies.

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