Postal / Bubble Lined Mailers / Envosafe Protect

See also: Envosafe Secure

Order Code	Description	Internal  Dimensions (mm)	Royal Mail	Pack Quantity
15MA000	Protect - white A/000	110 x 165	letter	200
15MB00	Protect - white B/00	120 x 215	letter	200
15MC0	Protect - white C/0	150 x 215	letter	100
15MD1	Protect - white D/1	180 x 265	large letter	100
15ME2	Protect - white E/2	220 x 265	large letter	100
15MF3	Protect - white F/3	230 x 335	large letter	100
15MG4	Protect - white G/4	240 x 335	large letter	100
15MH5	Protect - white H/5	270 x 360	packet	100
15MJ6	Protect - white J/6	300 x 445	packet	50
15MK7	Protect - white K/7	350 x 470	packet	50
15MK7	Protect - white K/7	350 x 470	packet	50

Postal Bubble Lined Mailers (Envosafe Protect) — Quick Overview

Bubble lined mailers are designed to protect items in transit while keeping parcels lightweight and easy to handle. This collection covers white “Protect” bubble mailers in common postal-friendly formats, with internal sizes ranging from 110 x 165 mm up to 220 x 265 mm. The range includes options typically used for letter and large-letter formats, helping you match packaging to both product size and mailing requirements.

Envosafe Protect — Helpful Guide

This category focuses on cushioned mailers that combine an outer envelope with an internal bubble lining. They are commonly used for shipping small, fragile, or scratch-prone items where a rigid box would be unnecessary. The key selection factors are internal dimensions, thickness of the contents, and how much clearance you need for easy insertion and sealing.

Types of packaging in this category

• White bubble lined mailers (Protect series)
  A general-purpose padded mailer format intended to reduce scuffing and minor impact damage during handling. Choose the size based on the internal dimensions shown on the page table.

  • Protect - white A/000 (Order code 15MA000) — internal 110 x 165 mm; commonly aligned with letter format for very small items.
  • Protect - white B/00 (Order code 15MB00) — internal 120 x 215 mm; letter format; useful when you need extra length for slim products.
  • Protect - white C/0 (Order code 15MC0) — internal 150 x 215 mm; letter format; a wider option for flat items.
  • Protect - white D/1 (Order code 15MD1) — internal 180 x 265 mm; large letter format; suited to larger flat goods and bundled items.
  • Protect - white E/2 (Order code 15ME2) — internal 220 x 265 mm; large letter format; for bulkier or wider items that still ship efficiently.

Case Study: Reducing Damage Without Switching to Boxes

A small fulfilment operation shipping mixed small goods (flat accessories, small components, and occasional fragile items) often starts with paper envelopes to keep postage low. Over time, customer returns can increase due to corner dents, surface scratches, or cracked low-profile items. Switching to bubble lined mailers can reduce these issues by adding cushioning while keeping the parcel flexible and lightweight. The practical improvement usually comes from (1) selecting the correct internal size so items don’t rattle, and (2) adding a simple internal wrap for sharp edges or heavy parts.

In day-to-day packing, the biggest gains typically come from standardising a small set of sizes (for example, one letter size and one large-letter size) and training packers to leave consistent clearance for sealing. This reduces packing time and helps maintain predictable parcel thickness.

How to Choose the Correct Bubble Lined Mailer

1) Measure the product correctly (and include protective layers)

Use the product’s length x width x thickness after any internal protection is applied (e.g., tissue, a small poly bag, or a thin foam sheet). Bubble lined mailers are sized by internal dimensions, so the usable space is the inside of the envelope, not the outside.

2) Allow clearance for easy insertion and reliable sealing

As a rule of thumb, leave a little extra room in both length and width so the item slides in without forcing. If you have to push the item into the mailer, you risk stressing the seams and creating a poor seal. Extra clearance also helps when packing multiple items together.

3) Consider thickness and postal format

The table on this page indicates typical postal format alignment (e.g., letter vs large letter). Thickness is often the limiting factor: even if an item fits in length and width, a bulky product can increase parcel depth. If your shipments vary, test-pack a sample item and check the final thickness after sealing.

4) Match cushioning to risk

Bubble lining helps with minor impacts and abrasion, but it is not a substitute for rigid protection when shipping highly fragile items. For sharp corners, heavy metal parts, or items with protrusions, add an internal wrap so the product doesn’t puncture the lining or outer film.

5) Choose the smallest size that fits comfortably

Oversizing can increase movement inside the mailer, which can lead to edge wear and corner damage. A snug-but-not-tight fit reduces shifting and helps the cushioning do its job. If you need to include paperwork, consider whether it should be folded or placed behind the item to keep the face protected.

Practical Packing Tips (to Improve Protection and Consistency)

• Keep labels flat: Apply shipping labels to a smooth area to reduce scanning issues and avoid wrinkles.
• Protect corners: For items with sharp edges, add a thin internal sleeve or wrap to prevent punctures.
• Prevent rattling: If there is spare space, add a small void-fill sheet so the item doesn’t slide.
• Seal cleanly: Ensure the sealing area is free from dust and product debris; press firmly along the full width.
• Batch by size: Keep the most-used sizes at the packing bench to reduce handling time and mistakes.

Common Use Cases by Size (Examples)

Exact fit depends on thickness and how flexible the contents are, but the internal dimensions on this page provide a reliable starting point:

• A/000 (110 x 165 mm): very small flat items, small components, or compact accessories.
• B/00 (120 x 215 mm): slim items needing extra length; small bundles where thickness stays low.
• C/0 (150 x 215 mm): wider flat items; multiple small items packed together.
• D/1 (180 x 265 mm): larger flat goods; thicker bundles that still suit large-letter handling.
• E/2 (220 x 265 mm): wider items and multi-item packs where you need extra width for easy insertion.

Storage, Handling, and Quality Checks

To keep mailers performing consistently, store them in a clean, dry area away from direct heat sources. Before packing, do a quick check for crushed corners or damaged seals (especially if cartons have been compressed in storage). During packing, avoid overfilling: forcing the flap closed can compromise the seal and increase the chance of opening during transit.

Questions & Answers