The Misconception of Corrugated Mailers

Authors: Hang Bui, Laura Baron, Sanket Rawat, Anh Ngo

With environmental sustainability being more important than ever, businesses and people are looking for green alternatives to traditional packaging materials. One such alternative is the corrugated paper-padded mailer, which has been tested and proven to offer comparable protection to the classic air-bubble mailer. But what sets these two products apart, and why should you consider switching to corrugated mailers? Recent tests[i] provide compelling evidence in favour of this environmentally friendly option.

The Misconception of Durability

A common misconception is that air-bubble mailers offer superior protection due to their cushioning bubbles. However, recent testing at the laboratory of the University of Canberra has debunked this myth. The lab conducted uniaxial tensile tests on samples from traditional air-bubble and corrugated paper-padded mailers.

The tests utilized samples approximately 100 mm in length, 20 mm in width, and 0.15 mm in thickness, subjected to a constant elongation rate of 1.0 mm/min. The resulting load-elongation curves indicated that corrugated mailers exhibit significantly better tensile capacity, outperforming air-bubble mailers by a factor of 1.4 in terms of protecting contents from shocks and damage (Figure 1). This enhanced performance is attributed to the unique design of corrugated mailers. The internal corrugation within the cardboard sheet provides added rigidity and resistance, allowing the mailer to absorb more energy before the contents are impacted.

Figure 1 Uniaxial tensile test setup and Comparison of force-elongation curves

This innovative structure ensures that your items remain secure and intact during transit, debunking the myth that only air-bubble mailers can provide sufficient protection.

A Step Towards Sustainability

Aside from its protective qualities, the corrugated paper-padded mailer shines as an ideal choice of sustainability. Unlike air-bubble mailers, which are composed of only 50% recycled content, corrugated mailers are made from 100% recyclable materials. This is a significant advantage for environmentally conscious consumers and businesses aiming to reduce environmental impacts.

The corrugated paper-padded mailer is certified with the FSC MIX label, indicating that it is made from a blend of materials sourced from FSC-certified forests, recycled materials, and FSC-controlled wood. The Forest Stewardship Council (FSC) certification ensures that the mailer is not only recyclable but also responsibly sourced. Once used, the corrugated mailer can be entirely recycled, promoting a circular economy and minimizing packaging waste. This commitment to sustainability significantly enhances the ecological appeal of corrugated mailers compared to their air-bubble counterparts.

Versatility and Practicality

The corrugated mailer has more benefits in practical terms than just being environmentally friendly. The paper surface is easier to write on compared to the plastic air-bubble mailers, facilitating labelling and addressing. Additionally, the corrugated mailer is designed to cater to a diverse range of needs and is available in various sizes to accommodate different items. This versatility means it can be used for a multitude of purposes, from shipping fragile photographs and essential documents to transporting books and other bulkier items, making it an indispensable tool for both personal and business use.

As the demand for sustainable packaging solutions grows, the corrugated paper-padded mailer stands out as an exceptional alternative to traditional air-bubble mailers. With its proven strength, superior recyclability, and practical advantages, it offers a compelling choice for those looking to make a positive environmental impact without compromising on protection. By choosing corrugated paper-padded mailers, individuals and businesses not only protect their goods during shipments, but also contribute to the circular economy and a more sustainable future.


[i] The test conducted by Hang Bui, Sanket Rawat, and Laura Baron at the University of Canberra analyzed the tensile strength and durability of corrugated paper-padded mailers in comparison to air-bubble mailers. The results were used to demonstrate the superior protective qualities of corrugated mailers.

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