What Size Poly Mailer for Hoodies, T-Shirts & Jeans?
The quick answer
Use a 10x13 in poly mailer for a folded T-shirt, a 12x15.5 in mailer for a hoodie, sweatshirt or jeans, and a 14.5x19 in mailer for thick or oversized hoodies, jackets and bulky knitwear. As a rule, leave 1–2 inches of room on each side of the folded item and 2–3 inches above it for the peel-and-seal strip.
That covers most orders. The chart below breaks it down garment by garment, and the sections after it explain how to fold, how thick the film should be, and what happens when you pick the wrong size.
Poly mailer size chart by garment
The sizes below follow JiaroPack's own poly mailer sizing guidance. Folded sizes are approximate: they vary with fabric, brand and how tightly you fold, so measure one real sample before you order a full case.
| What you are shipping | Typical folded size (approx.) | Recommended mailer | Suggested thickness |
|---|---|---|---|
| Thin tee, scarf, flat lightweight item | About 8 x 10 in or smaller | 7.5x10.5 in | 2–2.5 mil |
| Standard T-shirt, shorts, leggings | About 8 x 10 in | 9x12 in | 2–2.5 mil |
| T-shirt with room to spare, polo, folded top, dress | About 9 x 11 in | 10x13 in | 2.5–3 mil |
| 2–3 T-shirts in one order | About 9 x 11 in, 2–3 in thick | 12x15.5 in | 2.5–3 mil |
| Hoodie or sweatshirt (most adult sizes), jeans | About 10 x 12 in, 2–3 in thick | 12x15.5 in | 2.5–3 mil |
| Thick or oversized hoodie, jacket, bulky knitwear | About 12 x 15 in, 3+ in thick | 14.5x19 in | 3 mil or more |
| Large bundles, blankets, tote bags | Measure the bundle | 19x24 in or 24x24 in | 3 mil or more |
If an item sits between two sizes, go up one. A mailer that is a little too big still seals and ships fine. A mailer that is too small stretches at the seams and fails to seal.
Which size for each garment
T-shirts
A folded adult T-shirt usually fits a 10x13 in mailer with comfortable margins. If you ship lightweight tees and want to save on materials, 9x12 in works for a single, neatly folded shirt. For two or three shirts, move up to 12x15.5 in so the stack is not forcing the seams.
Hoodies and sweatshirts
A hoodie is the item people size wrong most often, because it is thick as well as wide. JiaroPack's 12x15.5 in mailer fits most adult hoodies and sweatshirts when they are folded compactly. If the hoodie is heavy fleece, an oversized cut, or XL and larger, use 14.5x19 in instead.
Jeans and pants
Folded jeans are bulky. Use 12x15.5 in for a single pair, and 14.5x19 in if you ship two pairs together or heavy denim.
Dresses, leggings and activewear
Soft, thin fabrics fold small. A 9x12 in or 10x13 in mailer handles most leggings, shorts and folded dresses.
Jackets and knitwear
Chunky sweaters and light jackets need 14.5x19 in, and sometimes 19x24 in. These take up volume rather than flat area, so a roll or a loose fold often fits better than a tight rectangle.
How to measure and fold for the right fit
- Fold the garment the way you will ship it. Fold once, press it flat, and keep it tight.
- Measure the width and the length of the folded stack. Note its thickness too.
- Add the allowance. Add 2–4 inches to the width (1–2 inches per side) and 2–3 inches to the length for the seal strip, plus a little extra if the item is thick.
- Pick the smallest mailer that meets both numbers and test one before you buy a case.
Check the size on the label of the mailer you plan to buy. JiaroPack sizes mailers by their width and height, and the flap sits on top of that: the 10x13 in mailer, for example, has a flap of about 1.6 in beyond the 13 in height.
How thick should a poly mailer be?
Thickness is measured in mils (one mil is a thousandth of an inch). JiaroPack's guidance matches film thickness to the weight of what you ship:
| Item weight | Recommended thickness | Typical use |
|---|---|---|
| Under 250 g (about 9 oz) | 2.0–2.5 mil | Lightweight apparel, documents |
| 250 g–1 kg (about 9 oz–2.2 lb) | 2.5–3.0 mil | Folded clothing, soft accessories |
| Over 1 kg (about 2.2 lb) | 3.0 mil or more | Heavier garments, multi-item orders |
Light T-shirts sit in the first band. A fleece hoodie or a pair of jeans usually lands in the second, and a multi-item bundle can reach the third. Weigh a packed sample on a kitchen scale to be sure. Darker or opaque film also hides the contents better, which matters for light-colored clothing.
What happens if you choose the wrong size?
- Too small: the seal strip cannot sit flat, the seams stretch, and the mailer can burst in transit.
- Too big: the garment slides around and creases, and you may pay more for postage if the package ends up larger than it needs to be. Extra space also makes a flimsy package.
- Too thin: heavy items can tear at the corners, and sharp zippers or buttons can puncture the film.
Common mistakes
- Ignoring thickness. Judging by width and length alone is why hoodies split mailers that looked big enough.
- Sizing from the flat garment. Measure the folded stack, not the garment laid flat.
- Forgetting the seal strip. Leave the 2–3 in clearance at the top, or the strip will not close cleanly.
- Buying one size for the whole catalog. Most stores need two or three sizes. Our guide to poly bags for shipping clothes covers matching sizes to a clothing range.
- Skipping the test pack. Pack and seal one real order before you commit to a full case.
Buying poly mailers in bulk for clothing
Poly mailers are sold by the case, and the case count depends on size. Here is what JiaroPack lists for the sizes most clothing sellers use:
| Size | Pack per case | Colors |
|---|---|---|
| 9x12 in | 1,000 | White, Sakura pink |
| 10x13 in | 1,000 | 12+ colors |
| 12x15.5 in | 500 | 12+ colors |
| 14.5x19 in | 500 | 15+ colors |
| 19x24 in | 500 | 8+ colors |
If you sell a mix of garments, a good starting point is one case of 10x13 in for tees and one of 12x15.5 in for hoodies and jeans, then add 14.5x19 in once you see how often you ship bulky items. Mixed sizes in one order are easier to plan when you buy them together, and we can quote that on our wholesale pricing page.
FAQ
What size poly mailer do I need for a hoodie?
Use 12x15.5 in for most adult hoodies and sweatshirts, folded compactly. Move up to 14.5x19 in for thick fleece, oversized cuts, or XL and larger.
What size poly mailer for a T-shirt?
A 10x13 in mailer fits a folded adult T-shirt comfortably. A single, thin, neatly folded shirt can go in 9x12 in.
What size poly mailer for jeans?
12x15.5 in for one pair. Use 14.5x19 in for two pairs or heavy denim.
What size poly mailer for clothes in general?
10x13 in and 12x15.5 in cover most clothing orders. Add 14.5x19 in for bulky items.
What thickness poly mailer is best for clothing?
2.5–3 mil suits most folded clothing. Use 2–2.5 mil for very light items and 3 mil or more for heavy garments or multi-item orders.
Should I go bigger than the garment?
Yes, a little. Leave 1–2 inches on each side and 2–3 inches above the garment for the seal strip.
Do poly mailers stretch?
Slightly, but you should not rely on it. A mailer that has to stretch to close is the wrong size.
Ready to order?
Browse JiaroPack poly mailers by size: 10x13 in, 12x15.5 in and 14.5x19 in, or see every poly mailer size and color. For bulk orders, request a wholesale quote.
Related reading: how to choose poly mailer dimensions, thickness and type, bubble mailer and poly mailer size chart, what is a poly mailer bag.
Sources
- JiaroPack: How to choose the right poly mailer dimensions, thickness, and type (sizing allowances, thickness by weight)
- JiaroPack: Bubble mailer and poly mailer size chart (sizes, colors, pack per case)
- JiaroPack: 12x15.5 poly mailers (what the size fits)
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