Padded mailers are more than just a shipping solution. They effectively protect electronics, books, clothing, and accessories at a fraction of the cost consumers would face if damaged, and they reduce the waste associated with heavier, bulkier packaging. While it is true that non-cushioned mailers (like poly envelopes) held 62% of the market share in 2024, it is padded mailers that grow exponentially due to their protective qualities and EU sustainability regulations (Grand View Research). By choosing the right padded mailers, businesses and consumers avoid excess materials, reduce carbon emissions, and save on shipping costs. Find out in this article which padded mailer solution will suit your business needs best…
Padded mailers have become the go-to packaging solution for e-commerce businesses looking to ship goods efficiently, securely, and cost-effectively. Among the most commonly used options are foam-lined mailers, aluminum foil mailers, and paper & plastic film bubble mailers—each with its own advantages depending on the product type.
Foam mailers are ideal for fragile, high-value items like electronics or cosmetics, offering excellent shock absorption. However, they are less cost-effective.
Aluminum mailers, while offering moisture and puncture resistance, tend to be heavier and more expensive, making them better suited for specialized items that require barrier protection. Paper bubble mailers strike the best balance for most businesses—they’re lightweight, recyclable, and offer solid protection for books, apparel, accessories, and small electronics. Their affordability and environmental compatibility make them a top choice in today’s e-commerce logistics.
FILMAR Classic Bubble Mailers are a staple in e-commerce packaging—affordable, protective, and versatile. Available in 12 size options ranging from 120×175+50 mm to 370×480+50 mm, they suit everything from small accessories to books and lightweight electronics. These mailers come in two neutral colors—white and brown—and can be customized on the outer part for branding or product messaging, making them a practical yet professional packaging choice.
Made with sustainability in mind, the outer paper layer contains 100% FSC-certified recycled fiber, while the inner bubble film includes a minimum of 50% recycled plastic. Though they are the most basic option in the padded mailer range, their certified recycled content and dual-material design make them a credible, eco-conscious solution for businesses seeking to reduce their packaging footprint.
Classic bubble mailers are ideal for companies aiming to optimize shipping costs by reducing parcel weight and dimensions. With built-in protection from the bubble wrap and a durable paper exterior, they offer two-in-one efficiency that simplifies logistics. For brands shipping across the EU, choosing recycled-content packaging is a smart move—not only for upcoming PPWR compliance, but also for strengthening brand perception and environmental credentials.
Eco Bubble Mailers are designed for businesses that prioritize sustainability without compromising on protection. Made from high-quality recycled materials, they offer the same protective benefits as classic mailers, while setting a higher environmental standard. Available in 12 size options from 120×175+50 mm to 370×480+50 mm, these mailers come in natural brown and can be custom printed inside and out for added brand visibility and eco-conscious messaging.
These mailers are produced using 90% recycled materials, including paper made from 100% FSC-certified recycled fiber, with 80% post-consumer recycled (PCR) content. The inner bubble wrap film contains a minimum of 70% recycled plastic, with 40% PCR content, making it one of the most sustainable options on the market. What’s more, the paper and film layers can be easily separated and recycled independently, ensuring end-of-life sustainability as well.
Eco Bubble Mailers are an excellent fit for companies looking to streamline logistics while showcasing a genuine commitment to sustainability. They represent the perfect balance between environmental responsibility and reliable product protection, ideal for EU markets with growing expectations for PPWR compliance and corporate social responsibility.
The FILMAR AroFair is a fully paper-based mailer that combines high-level protection with unmatched sustainability. Instead of traditional plastic bubble wrap, it features an innovative, shock-absorbent paper interior, making it a true mono-material packaging solution. Available in 4 sizes from 170 × 225 + 50 mm to 290 × 370 + 50 mm, AroFair is designed to protect a wide range of products without the need for additional padding or filling.
Made entirely from 100% FSC®-certified recycled brown paper (FSC-C014176), this mailer is fully recyclable via paper waste streams—no need to separate materials for recycling the mailer after use. It’s printed using water-based inks and features international environmental disposal icons, making it fully compliant with packaging guidelines in countries like France and Italy. Its mono-material design simplifies recycling and supports circular economy goals from start to finish.
AroFair is ideal for companies that are deeply committed to sustainability and want their packaging to reflect that. It’s a perfect match for eco-friendly brands that ship 100% sustainable products, prefer paper-only solutions, and want to enhance customer experience with packaging that aligns with their environmental values.
When selecting a shipping packaging solution, material composition and recyclability should be top priorities. Choose packaging made from mono-material paper or with high recycled content, as these options are easier to recycle and more sustainable. Clear recycling instructions are essential, not only to comply with regulations (especially in the EU), but also to promote responsible disposal among consumers. Prioritizing eco-friendly materials helps reduce environmental impact while reinforcing your brand’s commitment to sustainability.
Equally important are product protection, cost efficiency, and the overall customer experience. The packaging should be durable enough to protect items during transit, especially if you ship fragile or high-value goods. Cost efficiency involves more than just the price-per-unit – factor in storage, shipping rates, and potential losses from returns due to damaged goods. For operational ease and a smoother unboxing experience, look for features like easy-seal closures, tear strips, and compact designs. A well-chosen packaging solution balances protection, sustainability, and convenience, enhancing both internal workflows and customer satisfaction.
The Classic Bubble Mailer features an outer shell made from 100% recycled fiber, (also FSC-certified) offering durability and a clean, professional look. Its surface is fully customizable both inside and out, making it ideal for businesses wanting branded, protective packaging. The sturdy paper exterior also provides basic moisture resistance and protection against sharp or irregularly shaped items, making it a reliable option for various shipping needs.
The Eco Bubble Mailer elevates sustainability with an outer layer made of 100% FSC-certified recycled fiber, including 80% post-consumer recycled content (PCR). This composition not only enhances eco-credentials but also reinforces your brand’s commitment to the circular economy. Like the Classic version, it’s fully customizable inside and out, making it both a functional and responsible packaging choice.
The AroFair Mailer stands out with its 100% FSC-certified recycled brown paper exterior, which forms a seamless, mono-material package with the internal padding—meaning no separation is required for recycling. It’s fully customizable and ideal for lightweight items that need scratch and handling protection during shipping. With no plastic components, it offers a simple and highly sustainable solution for brands looking to minimize waste and maximize customer experience.
The Classic Bubble Mailer is lined with multilayer plastic bubble wrap, offering excellent shock absorption for everyday shipping needs. The bubble film is made with a minimum of 50% recycled materials, and the entire inner layer is RecyClass-certified, ensuring it meets recognized standards for plastic recyclability and content. This combination makes it a reliable and sustainable option for protecting a wide range of goods during transport.
The Eco Bubble Mailer builds on that foundation with an even more sustainable interior—its multilayer bubble wrap contains at least 70% recycled materials, including 40% post-consumer recycled (PCR) plastic content. Like the Classic version, it also holds the RecyClass certification, adding credibility to its environmental claims. It offers robust cushioning for sensitive items while aligning with circular economy goals and regulatory requirements.
Inside the AroFair Mailer, there’s no plastic at all. Instead, it features a patented button-like filling made from FSC-certified recycled paper and natural starch, providing shock-absorbing protection without synthetic materials. This design ensures full recyclability in paper streams, making AroFair an ideal choice for businesses committed to eliminating plastic and offering customers a fully paper-based, zero-separation solution.
The Classic Bubble Mailer is lined with multilayer plastic bubble wrap, offering excellent shock absorption for everyday shipping needs. The bubble film is made with a minimum of 50% recycled materials, and the entire inner layer is RecyClass-certified, ensuring it meets recognized standards for plastic recyclability and content. This combination makes it a reliable and sustainable option for protecting a wide range of goods during transport.
The Eco Bubble Mailer builds on that foundation with an even more sustainable interior—its multilayer bubble wrap contains at least 70% recycled materials, including 40% post-consumer recycled (PCR) plastic content. Like the Classic version, it also holds the RecyClass certification, adding credibility to its environmental claims. It offers robust cushioning for sensitive items while aligning with circular economy goals and regulatory requirements.
Inside the AroFair Mailer, there’s no plastic at all. Instead, it features a patented button-like filling made from FSC-certified recycled paper and natural starch, providing shock-absorbing protection without synthetic materials. This design ensures full recyclability in paper streams, making AroFair an ideal choice for businesses committed to eliminating plastic and offering customers a fully paper-based, zero-separation solution.
With new EU packaging rules under the Packaging and Packaging Waste Regulation (PPWR), the use of post-consumer recycled (PCR) materials is becoming not just a best practice, but a legal requirement. By 2030, many packaging types will need to include minimum percentages of PCR content, and by 2035, recyclability will become mandatory for all packaging placed on the EU market. Choosing packaging that already meets or exceeds these thresholds helps businesses future-proof their logistics and stay ahead of compliance.
Incorporating PCR materials into shipping solutions not only prepares companies for upcoming legislation, but also reduces their overall environmental impact. By giving a second life to consumer waste, PCR-based packaging reduces landfill dependency, conserves natural resources, and lowers greenhouse gas emissions associated with raw material extraction and processing. This aligns with the growing demand from both regulators and consumers for sustainable practices in the supply chain.
Moreover, companies that embrace PCR materials early can benefit from positive brand differentiation. Communicating the use of PCR content through clear labeling and transparency reports can help build consumer trust and loyalty. Businesses seen as proactive, rather than reactive, in adapting to environmental standards are more likely to attract partnerships and customers who prioritize sustainability as a core value.
Clear recycling instructions are key to ensuring that end-users dispose of packaging correctly. Mailers labeled with disposal symbols, instructions, and environmental claims guide consumers to separate paper and plastic (where necessary) or dispose of monomaterial mailers through the appropriate waste stream. This helps increase actual recycling rates and reduces contamination in municipal recycling systems—a win for both the brand and the environment.
However, even well-designed packaging can fall short if users don’t know how to dispose of it properly. Clear, simple recycling instructions—such as internationally recognized symbols, custom color-coded icons, or short guidance printed directly on the mailer—can dramatically improve recycling rates. When consumers understand how to separate or dispose of packaging components, contamination is minimized and municipal recycling systems can process materials more efficiently.
For businesses, ensuring packaging is both recyclable and clearly labeled represents a dual win: it contributes to sustainability goals and enhances brand image. Customers increasingly value companies that make it easier to “do the right thing,” and brands that facilitate this process demonstrate a genuine commitment to environmental responsibility. Over time, this can strengthen customer relationships and improve market competitiveness.
FILMAR’s packaging solutions are backed by trusted certifications that demonstrate both material integrity and environmental responsibility. These include FSC® certification for paper sources (FSC-C014176) and RecyClass certification for bubble films, verifying recycled content and recyclability. These certifications aren’t just labels—they’re recognized standards that help your brand build trust with eco-conscious customers and comply with national and EU-level environmental criteria.
By choosing certified packaging, companies can align themselves with both legal requirements and consumer expectations. Many procurement policies, especially among multinational companies and public institutions, increasingly require proof of environmental compliance through recognized certification schemes. In this context, using certified materials isn’t just preferable—it’s often necessary for participation in tenders or partnerships where sustainability is a key decision factor.
Furthermore, certifications provide powerful marketing and communication value. Displaying certified labels on shipping materials can signal a brand’s commitment to quality and sustainability. In a crowded marketplace, these indicators help differentiate responsible companies from competitors and build trust among environmentally conscious consumers and stakeholders.
The Packaging and Packaging Waste Regulation (PPWR) is the EU’s upcoming legislative framework aimed at reducing packaging waste and increasing circularity across all industries. A key element of the regulation is mandatory recyclability by 2030 for all packaging placed on the EU market, with additional requirements such as reduction of empty space in parcels, better consumer guidance through harmonized disposal labeling, and restrictions on unnecessary packaging formats. The regulation promotes mono-material packaging and design-for-recycling principles to simplify collection and sorting at end of life.
One of the most impactful measures of the PPWR is the introduction of minimum post-consumer recycled (PCR) content thresholds for plastic packaging. By 2030, the required minimums will be:
These percentages will increase by 2040, with 50% for contact-sensitive and 65% for other plastics. This makes early adoption of high-PCR-content packaging a smart and proactive move for businesses shipping across the EU.
FILMAR’s bubble mailers already comply with these upcoming standards. The Eco Bubble Mailer features bubble wrap made with 70% recycled materials, including 40% PCR content, exceeding 2030 thresholds for general plastic packaging. The outer paper layer is 100% FSC-certified recycled fiber, with 80% from post-consumer sources. The AroFair mailer, made entirely from FSC-certified recycled paper and using no plastic at all, is fully mono-material and recyclable, making it a future-proof solution for brands committed to full PPWR compliance.
Choosing European-made shipping packaging significantly reduces the carbon footprint of your logistics chain. Compared to overseas imports—especially from China—EU-to-EU transport produces far fewer greenhouse gas emissions, making a measurable difference in sustainability. All FILMAR bubble mailer variants, whether Classic, Eco, or AroFair, are manufactured within Europe, ensuring a shorter supply chain and more responsible emissions profile.
Another advantage of sourcing locally is access to raw materials with traceable, certified origins. FILMAR mailers use paper certified by FSC® and our products carry the Blauer Engel Eco-Label, confirming adherence to the highest European environmental standards. These certifications guarantee not only recycled content but also responsible forestry practices and low-impact production processes.
European manufacturing also ensures compliance with strict consumer safety, environmental, and packaging waste regulations. Our company carries the ISO certification, and our products include clear disposal symbols and recycling instructions, and are designed to meet local rules across diverse EU market. This makes European-sourced mailers not just safer and more sustainable—but also legally reliable and future-ready. 80% from post-consumer sources. The AroFair mailer, made entirely from FSC-certified recycled paper and using no plastic at all, is fully mono-material and recyclable, making it a future-proof solution for brands committed to full PPWR compliance.
In summary, with over 500 billion packages shipped globally each year, choosing the right mailer matters more than ever. Whether it’s the Eco Bubble Mailer, Classic Bubble Mailer, or AroFair, all three offer shared benefits: reliable protection, safety in transit, a wide range of sizes and uses, sustainable design, and customization options. The best choice depends on your business goals—go with the Classic if you’re focused on lowering costs, choose the Eco to highlight your sustainability commitment, or select AroFair to make recycling as easy and effective as possible.
Let us help you find the most sustainable packaging solution tailored to your e-commerce needs—get in touch today.
FILMAR Group’s product offer aligns with the growing consumer demand for sustainable packaging. Our solutions, such as Eco-Bubble Mailers represent this commitment. The products are crafted from sustainably sourced, recycled and recyclable materials, meeting both consumer expectations and regulatory requirements like the EU PPWR.
By choosing FILMAR’s eco-friendly packaging, companies can reduce their environmental impact, support recycling infrastructures, and enhance their brand reputation. Our customizable solutions not only contribute to a circular economy but also provide practical, sustainable options for businesses of all sizes.
Discover our certified, sustainable shipping envelopes and poly mailers:
