Mailers

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Padded Envelopes

Demand for mailers is projected to increase 7.2% annually to $3.2 billion in 2026, with advances supported by continued robust levels of e-commerce sales and concomitant gains in the total number of packages shipped. In addition, mailers will take share from corrugated boxes in the packaging of shipped parcels due to a number of advantages including:

  • lighter weight, which reduces shipping costs
  • lower material use, which aids in source reduction efforts
  • lower overall packaging costs, as mailers do not require void fill

New Curbside Recyclable Paper Mailers to Experience Strongest Gains

Curbside recyclable paper mailers will grow at the fastest rate of any mailer type, boosted by recent new product development by various companies to improve the sustainability as well as protective performance of paper mailers. These new mailers feature improved padding materials, making them fully curbside recyclable – unlike mixed material paper bubble mailers – while weighing less than traditional pulp padded mailers and offering comparable or improved protective capabilities. Usage by major e-commerce players such as Amazon will be a major factor in their strong growth.

Health & Personal Care Products to See Largest Gains in Mailer Demand

Though most every application will see healthy growth in mailer demand, health and personal care products are especially ideal for both e-commerce and mailer packaging, as online shopping offers increased selection and price comparison compared to in-store shopping, and these items tend to be small enough to fit snugly in mailers. In addition to large gains stemming from strong growth in e-commerce sales, these products will benefit from the continued popularity of mail order prescriptions.

Sustainability Remains a Primary Concern & Key Driving Force

Due to its single-use nature and high visibility to consumers, packaging remains at the center of many companies’ efforts regarding sustainability. In an effort to improve sustainability, companies are focusing on more easily recyclable monomaterial mailers, such as bubble mailers composed entirely of polyethylene, and padded paper mailers featuring recyclable cushioning. The new curbside recyclable paper mailers in particular will experience strong growth due to their recyclability but also due to improved strength and performance, which allows them to be used for larger packages and with products requiring greater protection.

Mailers Growth

E-Commerce Trends

E-Commerce Sales Outlook

The US is the second largest e-commerce market in the world, with online sales in 2021 totaling $736 billion. E-commerce has been quick to develop in the US due to the country’s:

  • cultural preference for convenience
  • highly developed network of stores and malls
  • consumers with a tendency to spend significant amounts of time online

E-commerce sales in the US are forecast to expand 9.8% annually to $1.2 trillion in 2026. The massive size of this market means that gains will be substantial, and although online sales have advanced rapidly, they still account for only a small share of overall retail activity.

Opportunities for increasing US e-commerce sales include expanding marketing and shopping through social media. Although these platforms are already established in some countries (such as China, where direct payments are offered via social media apps such as WeChat), they have a lower penetration in the US.

The most common products shipped via e-commerce include health and beauty products (including pharmaceuticals), clothing and accessories, and electronics. Most products will register strong growth in e-commerce sales.

Consumer Preferences

Changes to Shopping Habits Due to the COVID-19 Pandemic

Consumers changed a number of their shopping habits due to the COVID-19 pandemic, and while many of these habits involved increased use of shipping boxes, this could present opportunities for mailers. While some consumers report returning to pre-COVID-19 era habits, many have still retained the changes.

41% of respondents noted ordering items other than groceries online compared to pre-pandemic levels. While not all online orders are shipped in mailers, it is more common for smaller orders and lighter weight or soft products. Boxes are still a relatively common form of packaging for online orders such as groceries, subscription packages, and items that are larger, heavier, or more fragile.

Browsing in stores is one activity that a number of consumers reported doing less because of the COVID-19 pandemic. For instance, 40% of respondents noted that they were doing it less compared to before the pandemic. This is a habit change that benefits increased online shopping, and thus greater use of shipping mailers.

Frequency of Online Shopping

While online shopping is something almost all people do at some point in a year, the frequency of online shopping varies by demographic categories. Overall, the most frequent online shoppers are younger, urban, and higher income.

Consumers aged 18-54 are the most frequent online shoppers. More than half of those under 55 shop online at least once per week, and more than 80% in this group shop at least 2-3 times per month. In contrast, 29% of those 55-74 and 35% of those over 75 reported shopping online no more than once per month.

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  1. Mailers

    $2,900.00

    1. 1 Executive Summary

      $323.00

      1. Figure 1-1. US Mailer Market

    2. 2 COVID-19 Pandemic

      $330.00

      1. 2.1 Overview

        $323.00

      2. 2.2 Impact on the Economy

        $323.00

        1. Table | Macroeconomic Indicators: 2019 - 2023

        2. Figure 2-1. Real GDP by Economic Sector: 2020 - 2023

      3. 2.3 Impact on E-Commerce

        $323.00

      4. 2.4 Impact on the Mailers Industry

        $323.00

        1. Table | Annual Mailer Demand by Type & Market: 2019 - 2022

        2. Figure 2-2. Annual Mailer Demand by Type: 2019 - 2022

    3. 3 Overview

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      1. 3.1 Study Scope

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        1. Figure 3-1. Mailers: Product Examples

      2. 3.2 Historical Market Trends

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        1. Table | Annual Mailer Demand: 2011 - 2021

        2. Figure 3-2. Annual Mailer Demand: 2001 - 2021

      3. 3.3 Materials Trends

        $548.00

        1. 3.3.1 Demand by Primary Material

          $323.00

          1. Table | Mailer Demand by Material: 2011, 2016, 2021, &2026

          2. Table | Annual Mailer Demand by Material: 2018 - 2025

          3. Figure 3-3. Mailer Demand by Material: 2011, 2016, 2021, &2026

        2. 3.3.2 Plastic Mailers

          $323.00

          1. Table | Plastic Mailer Demand by Type & Market: 2011, 2016, 2021, &2026

          2. Table | Annual Plastic Mailer Demand by Type: 2018 - 2025

          3. Figure 3-4. Plastic Mailer Demand by Type: 2011, 2016, 2021, &2026

        3. 3.3.3 Paper & Paperboard Mailers

          $323.00

          1. Table | Paper & Paperboard Mailer Demand by Type & Market: 2011, 2016, 2021, &2026

          2. Table | Annual Paper & Paperboard Mailer Demand by Type: 2018 - 2025

          3. Figure 3-5. Paper & Paperboard Mailer Demand by Type: 2011, 2016, 2021, &2026

        4. 3.3.4 Mixed Material Mailers

          $323.00

          1. Table | Mixed Material Mailer Demand by Market: 2011, 2016, 2021, 2026

          2. Table | Annual Mixed Material Mailer Demand by Market: 2011, 2016, 2021, 2026

          3. Figure 3-6. Mixed Material Mailer Demand: 2011, 2016, 2021, 2026

        5. 3.3.5 Padding & Cushioning Materials

          $323.00

      4. 3.4 Pricing Patterns

        $323.00

        1. Table | Mailer Prices by Type: 2011, 2016, 2021, &2026

        2. Table | Annual Mailer Prices by Type: 2018 - 2025

        3. Figure 3-7. Mailer Prices by Type: 2011 - 2026

      5. 3.5 Foreign Trade

        $323.00

    4. 4 Factors Impacting Mailers Demand

      $2,513.00

      1. 4.1 Retail Sales Outlook

        $323.00

        1. Table | Retail Sales: 2011, 2016, 2021, &2026

        2. Table | Annual Retail Sales: 2018 - 2025

      2. 4.2 Manufacturing Outlook

        $323.00

        1. Table | Manufacturers’ Shipments: 2011, 2016, 2021, &2026

        2. Table | Annual Manufacturers’ Shipments: 2018 - 2025

      3. 4.3 E-Commerce Trends

        $349.00

        1. 4.3.1 E-Commerce Sales Outlook

          $323.00

          1. Table | E-Commerce Sales by Product Category: 2011, 2016, 2021, &2026

          2. Table | Annual E-Commerce Sales by Product Category: 2018 - 2025

        2. 4.3.2 Right-Sizing & Shipping Container Optimization

          $323.00

        3. 4.3.3 E-Commerce Ready Packaging

          $323.00

      4. 4.4 Annual Parcels/Packages Shipped

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        1. 4.4.1 Leading Shipping Companies

          $323.00

          1. Table | Annual Packages Shipped by Shipper: 2018 - 2021

        2. 4.4.2 Shipping Containers

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          1. Table | Packages Shipped by Shipping Container: 2011, 2016, 2021, &2026

          2. Table | Annual Packages Shipped by Shipping Container: 2018 - 2025

      5. 4.5 Packaging Trends

        $323.00

        1. 4.5.1 Sustainable Packaging

          $323.00

        2. 4.5.2 Reusable & Returnable Packaging

          $323.00

      6. 4.6 Sustainability Initiatives

        $323.00

        1. 4.6.1 Recycling & Recycled Content

          $323.00

        2. 4.6.2 Bioplastics

          $323.00

        3. 4.6.3 Source Reduction

          $323.00

        4. 4.6.4 Shipping Costs & Package Weight

          $323.00

      7. 4.7 Competitive Products

        $323.00

        1. Figure 4-1. Comparative Growth: Mailers & Boxes: 2021 - 2026

      8. 4.8 New Product Development

        $323.00

      9. 4.9 Consumer Preferences

        $1,290.00

        1. 4.9.1 Changes to Shopping Habits Due to the COVID-19 Pandemic

          $323.00

          1. Table | Changes to Shopping Habits Due to COVID-19 Pandemic, 2021

        2. 4.9.2 Frequency of Online Shopping

          $323.00

          1. Table | “How Often Do You Typically Shop Online?” Online Shopping Habits by Age Group, 2022

          2. Table | “How Often Do You Typically Shop Online?” Online Shopping Habits by Rural vs. Urban Setting, 2022

          3. Table | “How Often Do You Typically Shop Online?” Online Shopping Habits by Household Income Bracket, 2022

        3. 4.9.3 What Consumers Are Ordering Via E-Commerce

          $323.00

          1. Table | “What do you shop for online?” Online Shopping Habits by Age Group, 2022

          2. Table | “What do you shop for online?” Online Shopping Habits by Rural vs. Urban Setting, 2022

          3. Table | “What do you shop for online?” Online Shopping Habits by Household Income Bracket, 2022

        4. 4.9.4 Prevalence of Boxes in E-Commerce Home Deliveries

          $323.00

          1. Table | “What Share of Your Online Purchases Would You Estimate Arrive in Boxes, Instead of Paper or Plastic Mailers?” by Age Group, 2021

          2. Table | “What Share of Your Online Purchases Would You Estimate Arrive in Boxes, Instead of Paper or Plastic Mailers?” by Rural vs. Urban Setting, 2021

          3. Table | “What Share of Your Online Purchases Would You Estimate Arrive in Boxes, Instead of Paper or Plastic Mailers?” by Income Bracket, 2021

        5. 4.9.5 Online Order Shipping Habits

          $323.00

          1. Table | Online Order Shipping Habits, 2022

          2. Figure 4-2. “I often select the option to combine my orders into fewer packages.” by Gender, Age Group, Income Bracket, &Rural vs. Urban Setting, 2022

          3. Figure 4-3. “Most of my online orders are shipped with only one item per package.” by Gender, Age Group, Income Bracket, &Rural vs. Urban Setting, 2022

          4. Figure 4-4. “I have subscriptions/regularly scheduled delivery for items I order online.” by Gender, Age Group, Income Bracket, &Rural vs. Urban Setting, 2022

        6. 4.9.6 Recycling Awareness & Attitudes Toward Sustainability

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          1. Table | Recycling Awareness & Attitudes Toward Sustainability, 2022

        7. 4.9.7 Views on Safety of Packaging for Online Orders

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          1. Figure 4-5. “Boxes keep my e-commerce shipments safer than mailers/envelopes/bags.” by Gender, Age Group, Income Bracket, &Rural vs. Urban Setting, 2021

          2. Table | Consumer Attitudes about E-Commerce Package Safety, 2022

        8. 4.9.8 Opening Experience Attitudes

          $323.00

          1. Figure 4-6.“ A positive ‘unboxing’ experience (easy opening, attractive packaging) makes me more likely to buy again from the same online company.” by Gender, Age Group, Income Bracket, &Rural vs. Urban Setting, 2021

    5. 5 Product Types

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      1. 5.1 Demand by Type

        $323.00

        1. 5.1.1 Value Demand

          $323.00

          1. Table | Mailer Demand by Type: 2011, 2016, 2021, &2026

          2. Table | Annual Mailer Demand by Type: 2018 - 2025

          3. Figure 5-1. Mailer Demand by Type: 2011, 2016, 2021, &2026

        2. 5.1.2 Unit Demand

          $323.00

          1. Table | Mailer Demand by Type: 2011, 2016, 2021, &2026

          2. Table | Annual Mailer Demand by Type: 2018 - 2025

          3. Figure 5-2. Mailer Demand by Type: 2011, 2016, 2021, &2026

      2. 5.2 Bubble Mailers

        $585.00

        1. 5.2.1 Scope & Product Description

          $323.00

          1. Figure 5-3. Bubble Mailer Examples

        2. 5.2.2 Demand by Type

          $323.00

          1. Table | Bubble Mailer Demand by Type & Market: 2011, 2016, 2021, &2026

          2. Table | Annual Bubble Mailer Demand by Type: 2018 - 2025

          3. Figure 5-4. Bubble Mailer Demand by Type: 2011, 2016, 2021, &2026

        3. 5.2.3 Plastic (Poly) Bubble Mailers

          $323.00

          1. Table | Plastic Bubble Mailer Demand by Market: 2011, 2016, 2021, &2026

          2. Table | Annual Plastic Bubble Mailer Demand by Market: 2018 - 2025

          3. Figure 5-5. Plastic Bubble Mailer Demand by Market: 2011, 2016, 2021, &2026

        4. 5.2.4 Paper Bubble Mailers

          $323.00

          1. Table | Paper Bubble Mailer Demand by Market: 2011, 2016, 2021, &2026

          2. Table | Annual Paper Bubble Mailer Demand by Market: 2018 - 2025

          3. Figure 5-6. Paper Bubble Mailer Demand by Market: 2011, 2016, 2021, &2026

        5. 5.2.5 Other Bubble Mailers

          $323.00

          1. Table | Other Bubble Mailer Demand by Market: 2011, 2016, 2021, &2026

          2. Table | Annual Other Bubble Mailer Demand by Market: 2018 - 2025

          3. Figure 5-7. Other Bubble Mailer Demand by Market: 2011, 2016, 2021, &2026

      3. 5.3 Poly Mailers

        $464.00

        1. 5.3.1 Scope & Product Description

          $323.00

          1. Figure 5-8. Poly Mailer Examples

        2. 5.3.2 Demand by Type

          $323.00

          1. Table | Poly Mailer Demand by Type & Market: 2011, 2016, 2021, &2026

          2. Table | Annual Poly Mailer Demand by Type: 2018 - 2025

          3. Figure 5-9. Poly Mailer Demand by Type: 2011, 2016, 2021, &2026

        3. 5.3.3 Standard Polyethylene Mailers

          $323.00

          1. Table | Standard Polyethylene Mailer Demand by Market: 2011, 2016, 2021, &2026

          2. Table | Annual Standard Polyethylene Mailer Demand by Market: 2018 - 2025

          3. Figure 5-10. Standard Polyethylene Mailer Demand by Market: 2011, 2016, 2021, &2026

        4. 5.3.4 Other Poly Mailers

          $323.00

          1. Table | Other Polyethylene Mailer Demand by Market: 2011, 2016, 2021, &2026

          2. Table | Annual Other Polyethylene Mailer Demand by Market: 2018 - 2025

          3. Figure 5-11. Other Polyethylene Mailer Demand by Market: 2011, 2016, 2021, &2026

      4. 5.4 Paper Mailers

        $460.00

        1. 5.4.1 Scope & Product Description

          $323.00

          1. Figure 5-12. Paper Mailer Examples

        2. 5.4.2 Demand by Type

          $323.00

          1. Table | Paper Mailer Demand by Type & Market: 2011, 2016, 2021, &2026

          2. Table | Annual Paper Mailer Demand by Type: 2018 - 2025

          3. Figure 5-13. Paper Mailer Demand by Type: 2011, 2016, 2021, &2026

        3. 5.4.3 Padded Paper Mailers

          $323.00

          1. Table | Padded Paper Mailer Demand by Market: 2011, 2016, 2021, &2026

          2. Table | Annual Padded Paper Mailer Demand by Market: 2018 - 2025

          3. Figure 5-14. Padded Paper Mailer Demand by Market: 2011, 2016, 2021, &2026

        4. 5.4.4 Kraft Mailing Envelopes (Unpadded)

          $323.00

          1. Table | Kraft Mailing Envelope Demand by Market 2011, 2016, 2021, &2026

          2. Table | Annual Kraft Mailing Envelope Demand by Market: 2018 - 2025

          3. Figure 5-15. Kraft Mailing Envelope Demand by Market: 2011, 2016, 2021, &2026

      5. 5.5 Paperboard Mailers

        $323.00

        1. 5.5.1 Scope & Product Description

          $323.00

          1. Figure 5-16. Paperboard Mailer Examples

        2. 5.5.2 Demand Outlook

          $323.00

          1. Table | Paperboard Mailer Demand by Market: 2011, 2016, 2021, &2026

          2. Table | Annual Paperboard Mailer Demand by Market: 2018 - 2025

          3. Figure 5-17. Paperboard Mailer Demand by Market: 2011, 2016, 2021, &2026

      6. 5.6 Insulated Mailers (Foil, Cotton, &Foam-Lined)

        $323.00

        1. 5.6.1 Scope & Product Description

          $323.00

          1. Figure 5-18. Insulated Mailer Examples

        2. 5.6.2 Demand Outlook

          $323.00

          1. Table | Insulated Mailer Demand by Market: 2011, 2016, 2021, &2026

          2. Table | Annual Insulated Mailer Demand by Market: 2018 - 2025

          3. Figure 5-19. Insulated Mailer Demand by Market: 2011, 2016, 2021, &2026

    6. 6 Markets

      $1,012.00

      1. 6.1 Market Scope

        $323.00

      2. 6.2 Demand by Market

        $323.00

        1. Table | Mailer Demand by Market: 2011, 2016, 2021, &2026

        2. Table | Annual Mailer Demand by Market: 2018 - 2025

        3. Figure 6-1. Mailer Demand by Market: 2011, 2016, 2021, &2026

      3. 6.3 E-Commerce

        $708.00

        1. 6.3.1 Scope & Demand Outlook

          $323.00

          1. Table | E-Commerce Market for Mailers by Type & Market Segment: 2011, 2016, 2021, &2026

          2. Table | Annual E-Commerce Market for Mailers by Type: 2018 - 2025

          3. Figure 6-2. E-Commerce Market for Mailers by Market Segment: 2011, 2016, 2021, &2026

        2. 6.3.2 Retailers

          $323.00

          1. Table | E-Commerce Retailer Demand for Mailers by Type: 2011, 2016, 2021, &2026

          2. Table | Annual E-Commerce Retailer Demand for Mailers by Type: 2018 - 2025

          3. Figure 6-3. E-Commerce Retailer Demand for Mailers by Type: 2011, 2016, 2021, &2026

        3. 6.3.3 Third-Party Fulfillment & Logistics

          $323.00

          1. Table | Third-Party Fulfillment & Logistics Demand for Mailers by Type: 2011, 2016, 2021, &2026

          2. Table | Annual Third-Party Fulfillment & Logistics Demand for Mailers by Type: 2018 - 2025

          3. Figure 6-4. Third-Party Fulfillment & Logistics Demand for Mailers by Type: 2011, 2016, 2021, &2026

        4. 6.3.4 Other E-Commerce Markets

          $323.00

          1. Table | Other E-Commerce Demand for Mailers by Type: 2011, 2016, 2021, &2026

          2. Table | Annual Other E-Commerce Demand for Mailers by Type: 2018 - 2025

          3. Figure 6-5. Other E-Commerce Demand for Mailers by Type: 2011, 2016, 2021, &2026

      4. 6.4 Other Markets (Manufacturers, Consumers, &Mail Order)

        $323.00

        1. Table | Other Markets Demand for Mailers by Type: 2011, 2016, 2021, &2026

        2. Table | Annual Other Markets Demand for Mailers by Type: 2018 - 2025

        3. Figure 6-6. Other Markets Demand for Mailers by Type: 2011, 2016, 2021, &2026

    7. 7 Applications

      $1,005.00

      1. 7.1 Demand by Application

        $323.00

        1. Table | Mailer Demand by Application: 2011, 2016, 2021, &2026

        2. Table | Annual Mailer Demand by Application: 2018 - 2025

        3. Figure 7-1. Mailer Demand by Application: 2011, 2016, 2021, &2026

      2. 7.2 Apparel & Accessories

        $323.00

        1. Table | Apparel & Accessories Mailer Demand by Type: 2011, 2016, 2021, &2026

        2. Table | Annual Apparel & Accessories Mailer Demand by Type: 2018 - 2025

        3. Figure 7-2. Apparel & Accessories Mailer Demand by Type: 2011, 2016, 2021, &2026

      3. 7.3 Health & Personal Care

        $323.00

        1. Table | Health & Personal Care Products Mailer Demand by Type: 2011, 2016, 2021, &2026

        2. Table | Annual Health & Personal Care Products Mailer Demand by Type: 2018 - 2025

        3. Figure 7-3. Health & Personal Care Products Mailer Demand by Type: 2011, 2016, 2021, &2026

      4. 7.4 Multimedia & Software

        $323.00

        1. Table | Multimedia & Software Mailer Demand by Type: 2011, 2016, 2021, &2026

        2. Table | Annual Multimedia & Software Mailer Demand by Type: 2018 - 2025

        3. Figure 7-4. Multimedia & Software Mailer Demand by Type: 2011, 2016, 2021, &2026

      5. 7.5 Toys, Games, &Sporting Goods

        $323.00

        1. Table | Toys, Games, &Sporting Goods Mailer Demand by Type: 2011, 2016, 2021, &2026

        2. Table | Annual Toys, Games, &Sporting Goods Mailer Demand by Type: 2018 - 2025

        3. Figure 7-5. Toys, Games, &Sporting Goods Mailer Demand by Type: 2011, 2016, 2021, &2026

      6. 7.6 Other Applications

        $323.00

        1. Table | Mailer Demand for Other Applications by Type: 2011, 2016, 2021, &2026

        2. Table | Annual Mailer Demand for Other Applications by Type: 2018 - 2025

        3. Figure 7-6. Mailer Demand for Other Applications by Type: 2011, 2016, 2021, &2026

    8. 8 Suppliers & Market Share

      $979.00

      1. 8.1 Industry Composition

        $323.00

        1. Table | Mailer Sales by Company, 2021

      2. 8.2 Market Share

        $323.00

        1. Figure 8-1. US Mailer Market Share by Company: 2021

        2. Figure 8-2. US Mailers Market: Leading Supplier, 2021

        3. Figure 8-3. US Mailers Market: Second Leading Supplier, 2021

        4. Figure 8-4. US Mailers Market: Third Leading Supplier, 2021

        5. Figure 8-5. US Mailers Market: Fourth Leading Supplier, 2021

      3. 8.3 List of Industry Participants

        $700.00

        1. Table | List of Industry Participants

    9. 9 Appendix

      $1,501.00

      1. 9.1 Report Details

        $323.00

        1. Table | Relevant Industry Codes

        2. Table | Relevant HS Codes

      2. 9.2 Definitions

        $323.00

      3. 9.3 Abbreviations

        $323.00

        1. Table | Abbreviations & Acronyms Used in Study

      4. 9.4 Freedonia Methodology

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      5. 9.5 Study-Specific Methodology

        $323.00

      6. 9.6 Sources

        $323.00

      7. 9.7 Associations & Agencies

        $323.00

      8. 9.8 Related Studies & Reports

        $323.00

      9. 9.9 Macroeconomic Assumptions

        $812.00

        1. 9.9.1 Economic Environment

          $323.00

          1. Table | Macroeconomic Indicators 2011, 2016, 2021, &2026

        2. 9.9.2 Demographic Trends

          $323.00

          1. Table | Population & Households 2011, 2016, 2021, &2026

        3. 9.9.3 Consumer Spending

          $547.00

          1. Table | Personal Consumption Expenditures, 2011 - 2026

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