U.S. Mailer Packaging Market Size To Reach $24.38 Billion By 2033

U.S. Mailer Packaging Market Growth & Trends

The U.S. mailer packaging market is anticipated to reach USD 24.38 billion by 2033 and is anticipated to expand at a CAGR of 15.1% during the forecast period, according to a new report by Grand View Research, Inc. Rapid growth in U.S. e-commerce continues to be the primary force behind rising demand for mailer packaging. As more retailers adopt direct to consumer models, they need lightweight yet protective packaging to reduce both carrier costs and product damage. Non cushioned mailers made from kraft paper or polyethylene have become especially popular for apparel, small electronics, and documents due to their cost-effectiveness and ease of use. For instance, businesses shipping subscription boxes or small goods increasingly rely on paper-based mailers that combine light weight with sufficient durability.

Environmental concerns are reshaping the market. In the U.S., rising regulations limiting single-use plastics-alongside growing consumer preference for eco-friendly options-are driving adoption of recyclable and compostable mailers. Major players like Amazon have moved away from plastic-padded mailers, favoring paper alternatives. Companies are innovating with biopolymer coatings, soy-based inks, and water-based adhesives, enabling mailers that are not only greener but also attractive on the shelf or during unboxing.

The packaging itself has become a marketing tool. Brands seek mailers that stand out through customization-custom printing, tamper-evident closures, or unique materials-to enhance the unboxing experience and strengthen brand recall. Digital print-on-demand technologies allow for small-batch personalized designs, while features like self-sealing strips and tailored gussets meet both functional needs and aesthetic expectations. This trend is especially visible in beauty, subscription boxes, and boutique apparel, where memorable packaging boosts sales and social media visibility.

The increasing automation of fulfillment centers across the U.S. is also fueling demand for mailer packaging that is compatible with high-speed packing machinery. Major logistics providers and e-commerce companies such as Amazon and FedEx are investing in automated systems that require standardized, machine-friendly packaging formats like poly mailers and paper mailers with self-sealing features. This has pushed manufacturers to innovate with durable, easy-to-process materials that reduce friction in automated packaging lines while ensuring product protection. For example, mailers with peel-and-seal closures or pre-printed barcodes enhance workflow efficiency and reduce labor costs, making them essential in high-volume distribution environments.

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U.S. Mailer Packaging Market Report Highlights

• The non-cushioned mailers segment accounted for the largest share of over 60.0% of the market in 2024.

• The cushioned mailers segment is expected to grow at the fastest CAGR of 15.6% during the forecast period.

• The non-insulated mailers segment accounted for the largest share of over 90.0% of the market in 2024.

• The insulated mailers segment is projected to grow at the fastest CAGR of 15.5% during the forecast period.

• The paper segment accounted for the largest share of over 50.0% of the market in 2024 and is projected to grow at the fastest CAGR of 15.3% during the forecast period.

• Based on end use, the e-commerce segment dominated the U.S. Mailer Packaging market in 2024, accounting for the largest revenue share of over 50.0% and is expected to grow at the fastest CAGR of 15.5% over the forecast period.

U.S. Mailer Packaging Market Segmentation

Grand View Research has segmented the U.S. mailer packaging market on the basis of product, insulation, material type, and end use:

U.S. Mailer Packaging Product Outlook (Revenue, USD Million, 2021 - 2033)

• Non-cushioned Mailers

• Cushioned Mailers

U.S. Mailer Packaging Insulation Outlook (Revenue, USD Million, 2021 - 2033)

• Non-Insulated

• Insulated

U.S. Mailer Packaging Material Type Outlook (Revenue, USD Million, 2021 - 2033)

• Paper

• Plastic

• Foil

U.S. Mailer Packaging End Use Outlook (Revenue, USD Million, 2021 - 2033)

• E-commerce

• Shipping & Logistics

• Manufacturing & Warehousing

• List of Key Players in the U.S. Mailer Packaging Market

• Mondi

• Henkel Corporation

• 3M

• Pregis LLC

• International Paper

• PAC Worldwide

• Sealed Air

• Pregis LLC

• ProAmpac

• Novolex

• Intertape Polymer Group (IPG)

• Georgia-Pacific LLC