Hover to zoomCustom Reusable Mailers with a Spare Seal Strip for Returns
From $0.30 a box Exact price in your emailed quote
Reusable mailers carry two adhesive strips, so one bag can ship the order and then go back to you. We print them with your brand and the return steps.
Quick answer
What are reusable mailers?
A reusable mailer is a plastic shipping bag with two seal strips instead of one. The first strip closes the bag at your dock. The second strip lets the customer close it again for a return.
Key facts
- Two adhesive seal strips
- Tear strip for clean opening
- Return steps printed on bag
- Opaque, tough plastic film
- From $0.30 a box
- Free design proof
Reusable Mailers specifications
18 rows| Bag type | Flat bag with a deep flap |
|---|---|
| First seal | Peel-and-seal strip you use at packing |
| Second seal | Spare strip under its own liner for the return |
| Opening | Perforated tear strip under the first seal |
| Film | Opaque plastic in white, gray or a printed color |
| Outside, front and back, with return steps | |
| Sizing | Flat width × length, flap not counted |
| Price | From $0.30 a box; exact figure sent by email |
| Board options | E, B or C flute single wall; BC flute double wall; kraft or white paperboard |
| Printing | Unprinted, one color, two color or full color CMYK, outside and inside |
|---|---|
| Finishes | Natural kraft left uncoated, matte or gloss laminate, spot UV, foil stamping or embossing |
| Sizes | Built to your inside length × width × height in inches (mm also fine) |
| Artwork files | Vector PDF, AI, EPS or SVG work best; sharp PNG or JPG also accepted |
| Design help | Our designers set up the layout for free |
| Proof | Free design proof to approve before printing starts |
| Production | 4–6 business days once you approve the proof |
| Shipping | Free and tracked to any US address, 2–3 business days in transit |
| Misprints | Send photos within 10 days for a reprint or a refund |
Common sizes
| Flat size (W × L) | Good for |
|---|---|
| 7.5 × 10 in | Belts, scarves and folded socks |
| 9.5 × 12.5 in | T-shirts, tank tops and skirts |
| 12 × 16 in | Jeans, sweaters and dresses |
| 14 × 19 in | Folded jackets and two-item orders |
| 17 × 22 in | Bulky knits and multi-item returns |
What are reusable mailers?
A reusable mailer is a plastic mailing bag built for two trips. The flap carries two adhesive strips, each under its own peel liner.
You seal the first strip when the order leaves your dock. The customer opens the bag along a perforated tear strip, and the second strip stays untouched on the flap.
To send an item back, they refill the bag, peel the second liner and press it shut. No new box and no hunt for tape.
Which businesses get the most from reusable mailers?
Any seller with steady returns. Apparel is the clear match, because online shoppers often order two sizes and keep one.
Small shops can start with one size and grow from there. Our page on packaging made for small businesses covers other low-minimum options.
- Etsy and Shopify clothing shops with fit-based returns
- Subscription boxes that collect last month's items
- Rental wardrobes that expect every garment back
- Uniform suppliers swapping sizes for offices and restaurants
- Warehouses sending parts out for repair and back again
How does a return work with a reusable mailer?
It works best when the customer knows the steps. Print them on the bag and repeat them on the packing slip or in your shipping email.
- Your team packs the order and peels only the first liner.
- The customer tears along the perforation to open the bag.
- For a return, they put the item back inside.
- They peel the second liner and press the flap down firmly.
- They cover the old label with the return label and drop the bag off.
What size reusable mailer should I order?
Measure your biggest typical order folded flat, not a single item. Returns often include tissue, a hang tag or the packing slip.
Add the folded thickness to both the width and the length, then add about 1 in. Shoppers rarely fold as neatly as your packers.
The deep flap does not add room inside the bag. Our guide to measuring your packaging shows how to take a clean measurement.
| Typical order | Folded thickness | Bag to start with |
|---|---|---|
| One top or skirt | Up to 3/4 in | 9.5 × 12.5 in |
| Jeans or a sweater | 3/4 to 1.5 in | 12 × 16 in |
| Two items or a light jacket | 1.5 to 2.5 in | 14 × 19 in |
| Chunky knits or a set of pieces | Over 2.5 in | 17 × 22 in |
What should I print on a reusable mailer?
Start with your logo on the front. Choose one color, two colors or full color CMYK, on the outside, front and back.
Next, add a short instruction near the flap, such as tear here, then reseal with the second strip. That one line prevents most return mishaps.
Leave clear panels for the shipping label and the return label. Two barcodes in one spot can confuse scanners. You can try your layout in Design Your Box before you send files.
How do I pack a reusable mailer so it survives the round trip?
The bag has to look good after the first journey. A few habits at the packing bench make that easy.
Fold items without hard creases at the bag corners. Press out the air, then seal the first strip only.
Keep tape away from the tear strip and the spare strip. Tape there can tear the flap when the customer opens it.
Slip in a packing slip with a one-line reminder about the second strip. Customers who see the reminder usually reseal the bag correctly.
What mistakes do sellers make with reusable mailers?
The biggest one is ordering a bag that barely fits. A refolded return is bulkier than the original, so the flap may not close.
Another is leaving off the printed steps. Without them, some customers rip the bag open from the side and lose the spare strip.
Packers also peel both liners by habit. Show new staff that only the first liner comes off. A small sign above the bench works well.
Should I use a reusable mailer or a box?
Bags suit soft goods that fold flat. They are light, store compactly and keep shipping weight low.
Boxed shoes, gifts and breakable items need more protection. Look at reusable boxes for heavier returns for that job.
Many brands use both. Apparel goes in the bag and accessories go in a small box. Matching print makes the two look like one family.
Do reusable mailers save money?
Each bag costs a bit more than a single-strip mailer, because of the extra strip and tear feature. In return, customers stop improvising with grocery bags and old boxes.
Returns in your own branded bag are easier to spot and sort at receiving. Your team handles identical bags faster than a pile of mixed packages.
For the bigger picture, read how to lower your shipping costs.
How do I order reusable mailers?
Send us the flat size, film color, artwork and quantity. We take low minimums, quoted per job. Pricing starts from $0.30 a box, and the exact figure arrives in your quote by email within one business day.
The design proof is free, and our designers can lay out the return steps for you. You can also request a quote by email right now.
Once the proof is approved, printing and making your bags runs 4–6 business days. Shipping is free and tracked to any US address, with 2–3 business days in transit.
What if my reusable mailers arrive with a problem?
If a strip will not stick, the print looks wrong or the bags arrive damaged, send photos within 10 days. We will reprint the order or refund it.
Test a few bags from each carton before a busy season. Seal one, tear it open and reseal it with the spare strip, just as a customer would.
Reach us at (503) 461-4788 or info@ordercardboardboxes.com, Monday to Friday, 9 am to 6 pm Eastern. WhatsApp works too.
Reusable Mailers: questions
12 answersHow many times can one reusable mailer be closed?
Twice. The bag has two separate adhesive strips, one for the outgoing order and one for the return.
How does a shopper open the bag without damaging it?
They pull the perforated tear strip below the first seal. The spare strip stays on the flap, ready for use.
Can the return steps be printed on the bag?
Yes. Most sellers print two or three short steps near the flap, and our designers will lay them out.
Is the film see-through?
No. The plastic is opaque, so the contents stay private both ways.
Which size holds a pair of jeans?
Folded jeans usually fit a 12 × 16 in bag. Pick the next size up if returns tend to be bulky.
Can the return label go over the first label?
Yes. A marked blank panel for the return label keeps the old barcode from causing scan errors.
Will packing tape hurt the bag?
Tape over the tear strip or spare strip can rip the flap. Use only the first strip at packing.
Do reusable mailers cost more than single-strip bags?
Slightly, since they have an added strip and tear feature. Pricing starts from $0.30 a box, and the exact figure comes by email.
Can I print in full color?
Yes. Choose plain, one color, two color or full color CMYK, inside and outside.
Are these bags right for boxed shoes?
No. They suit soft goods. Shoes in a carton travel better in a box made for returns.
How soon will I receive printed bags?
Production takes 4–6 business days after proof approval. Free tracked shipping then takes 2–3 business days.
Can one order include several sizes?
Yes. Many apparel shops quote a small and a large bag together, plus a middle size if orders vary.
Still have a question? Phone (503) 461-4788, send our team a WhatsApp message or write to info@ordercardboardboxes.com.
Design Your Box
Pick a box photo, drop your logo onto it, choose the print and send it over. Our designers return a free proof ready for printing.
1Choose a box
2Place your logo
Add your logo to preview it on this box
Selected: Reusable Mailers
Tell us about your boxes
Share the inside size, the board you want and how it should be printed. Our team emails a quote and a free design proof within one business day.
- Free design proof before any box is printed
- Made in 4–6 business days after you approve the proof
- Free tracked shipping to any US address
Rather talk it through? Phone (503) 461-4788 or chat with us on WhatsApp.