2025 Cheapest Way to Ship Clothes for Sellers: Poly Mailer Guide

May 13, 2025by stoneGSS

Efficiently shipping clothing is an important component of running a successful online store. Among all options, the cheapest way to ship clothes is often by using poly mailers. Poly mailers are lightweight, inexpensive, and accepted by all major carriers in the United States.

How Online Sellers Ship Clothes in the US

Many online clothing sellers face the same challenge of protecting clothes while keeping things inexpensive. The choice can be all dependent on the clothes, brand image, and how they feel, as much protection needs to be given to the order. Some sellers enjoy the experience of opening a box and feel it brings a premium experience. Other sellers simply rely on poly mailers, considering they are the fastest and most cost-effective. In either case, it is beneficial to compare the most used options and see which you feel fits your business the best.

Popular Packaging Options

The right shipping choice is imperative when balancing cost, protection, and customer experience. Here is a brief comparison of a few of the more common options when shipping apparel.

Packaging Type	Average Cost	Durability	Protection Level	Eco-Friendliness	Best For
Poly Mailers	$0.10 - $0.50	High	Moderate	Varies (recycled options available)	T-shirts, pants, dresses, lightweight clothing
Mailer Boxes	$0.75 - $2.50	Very High	High	Good (often recyclable)	Structured garments, fragile garments, premium branding, delicate fabrics
Padded Mailers	$0.30 - $1.00	High	Moderate-high	Varies	Items with buttons, zippers, or embellishments, lingerie, small accessories
Shipping Envelopes	$0.20 - $0.70	Moderate	Low	Good (often paper-based)	Very small, flat items like socks
Reusable Bag/Envelope	$0.70 - $3.00	High	Varies	Eco-friendly but pricier	Eco-conscious brands

Why Poly Mailers the Most Popular Choice for E-commerce

Poly mailers are the most popular option for almost every online clothing store, and for good reason.

Cost Efficiency: They are much cheaper to buy than boxes, and if you are shipping a lot of orders, the savings can quickly add up.
Lower Postage: They are very light and flexible, which means they will help keep your overall package weight down. This reduces your shipping costs, particularly for services that charge for shipping based on weight and dimension.
Easy Bulk Storage: Poly mailers are thin and take up very little space. You can store hundreds or even thousands of them in a small area, which is perfect for sellers operating from home or a small warehouse.
Wide Carrier Acceptance: All of the major carriers (USPS, UPS, FedEx, etc.) accept poly mailers for normal shipping services.

Poly Mailer Size Chart for Clothes

Clothing Item	Suggested Poly Mailer Size
Underwear / Lingerie	6×9 in or 7×10 in
T-shirts	9×12 in
Light Dresses / Tops	10×13 in
Pants / Jeans	10×13 in or 12×15.5 in
Hoodies	14.5×19 in
Jackets / Sweaters	19×24 in
Baby Clothes / Small Accessories	6×9 in
Bulkier Winter Wear	19×24 in or 24x24 in or larger

Note: Always select a mailer that is slightly larger for thicker fabric, or if shipping multiple items in one order. This prevents you from over-extending the mailer, which eases sealing and helps maintain the shape of the clothing.

How to Ship Clothes With Poly Mailers

First, place your neatly folded clothing item into a protective inner packaging bag. This is optional, but recommended to protect from spills if the mailer is wet. For extra care, if using higher-end or delicate fabric, you may want to add tissue paper or a thin layer of protective material inside the poly mailer, but it's not necessary.
Next, place the bagged clothing item into the mailer. Gently push down on the item to relieve any excess air, so it's not increasing bulk.
Then, seal the mailer by securely pressing the voided adhesive strip. Use the palm of your hand and/or the palm of your hand to run your hand along the mailer seal (never fully sealing or closing), ensuring the seal is fully pressed together and secured.
After you have sealed the mailer, print your shipping label and securely attach it to an open, flat space on the mailer.
Finally, weigh the package to verify (double-check) the shipping cost with your carrier. Make sure you check the (USPS, UPS, FedEx) specific carrier weight limits (if any).

Most online sellers will ship lightweight clothing items using the USPS Ground Advantage or USPS Priority Mail services. Heavier-weight items and larger protective packages may be simpler, safer, and cheaper to book ships using the UPS or FedEx Ground services.

Where to Buy Shipping Bags for Clothes

Choosing the right shipping bags for clothes helps you protect your garments while keeping your fulfillment budget low. For durable and affordable packaging, shop poly mailer options available in many sizes. JiaroPack stands out because it offers:

Variety of colors — match your brand and create a better unboxing experience.
Full range of sizes — from small mailers for underwear to large ones for jackets and bulkier clothing.
Thicker, stretch-resistant material — keeps garments safe during shipping.
Strong adhesive seal — stays secure even in rough handling.
Waterproof protection — keeps clothes dry in transit.
Budget-friendly pricing — great value for bulk purchases.
Multiple US warehouses — free and fast shipping from Los Angeles, Houston, and New Jersey.

Conclusion

Poly mailers are a fantastic option for online clothing retailers. They won't keep your shipping costs high, they are lightweight for packaging, and they keep the fulfillment process simple. When selecting the proper poly mailer size and packaging your items correctly, you can guarantee that your garments arrive at their destination both safe and looking professional.

FAQs

What size bag is best for shipping clothes?

The best size depends on the clothing item. A 10×13-inch mailer is the most versatile size, perfect for t-shirts, dresses, and pants. For hoodies or bulkier items, you'll need a larger size, like 14.5×19 inches.

What size poly mailer for hoodies?

A 14.5×19 inch poly mailer is typically the best fit for a single hoodie. If the hoodie is particularly thick or oversized, you may want to size up to a 19×24 inch mailer to be safe.

What is the cheapest way to ship clothes for my online store?

For lightweight clothes under 16 ounces, USPS Ground Advantage Mail is often the most affordable option. For heavier items, compare USPS Priority, UPS Ground, and FedEx Ground to find the lowest rate.

Can I ship clothes in just a poly mailer without a box?

Absolutely! Poly mailers are specifically designed to be durable and weather-resistant, making them perfectly safe for shipping most types of clothing without an additional box.

Are poly mailers waterproof for clothing shipments?

Yes, high-quality poly mailers are made from polyethylene, a type of plastic that is highly water-resistant. They provide excellent protection against rain, snow, and moisture during transit.

Do I need extra padding for delicate or premium garments?

For items that have delicate bead, sequin, or sharp button details, it is better to use a padded mailer or wrap the item in bubble wrap before placing it in the poly mailer. For high-end apparel, wrapping it in tissue paper is a nice touch to also add extra protection.