Poly Bubble Mailer Production Process
From raw-material selection to dispatch, we work with a quality-control principle at every stage. Here are the key steps in the production process of our air-bubble lined (padded) protective shipping envelopes.
- 🧪1
Raw-Material Selection
Our production process begins with the careful selection of high-strength polyethylene film raw material. The right polymer is chosen for the inner air-bubble (padded) lining, and the correct recipe is formulated for the outer film (matte black, glossy silver-metallic or matte white).
- 🫧2
Air-Bubble (Padded) Film Extrusion
The polyethylene film is inflated in special molds, trapping evenly sized air bubbles inside. This bubble layer acts as a cushion that protects the product against impact and vibration.
- ✨3
Outer Surface Coating and Color
The outer surface is coated as matte black, glossy silver-metallic or matte white polyethylene film. This layer forms a barrier against moisture, water and UV exposure and gives the envelope a professional appearance.
- 🪞4
Lamination
The outer polyethylene film and the inner air-bubble lining are bonded together on the lamination line. This process keeps the layers from separating and ensures the envelope maintains its integrity against impact, scratches and moisture.
- ✂️5
Cutting and Edge Sealing
For the 7 standard sizes (from 10x15 up to 40x50 cm, with a +5 cm flap allowance), the laminated film is cut precisely; its edges are heat-sealed to form the envelope shape. A self-adhesive strip + protective liner is applied to the top edge.
- 🪪6
Adding the Invoice Pocket
On pocket models, a transparent waybill/invoice pocket is attached to the front face, so that documents and the shipping barcode can be read from the outside without opening the envelope.
- 🔍7
Quality Control
Every production batch undergoes checks for bubble-lining integrity, edge-seal strength, adhesive-strip testing and metallic coating. Products that do not meet our standards are removed.
- 📦8
Piece Counting and Dispatch
Made-to-order products are placed into tiered packs of 10,000/20,000/30,000/40,000/50,000 pcs on the automatic counting line, then dispatched within 3 business days via our partner carriers to all of Turkey.
The Main Functions of a Poly Bubble Mailer
A poly bubble mailer provides versatile protection so that fragile and valuable products are delivered safely against impact, scratches and moisture in e-commerce shipments.
- 🫧Protect fragile and delicate products against impact and vibration
- 💧Protect products against rain and moisture (metallic barrier)
- 🛡️Provide surface protection against scratches and abrasion
- 🔒Secure closure with a self-adhesive strip
- 🪪Easy external document handling on pocket models
- 📑Safely carry waybills, invoices and dispatch notes
- 🌍Reduce shipping weight and cost thanks to a lightweight structure
The Properties a Poly Bubble Mailer Film Should Have
The outer metallic polyethylene film + inner air-bubble (padded) lined structure we use in production meets all of the criteria below.
- 🫧The inner air-bubble (padded) lining must absorb impact
- 💪Must have high mechanical strength
- 🪶Must be lightweight
- 🛡️Must have high tear and puncture resistance
- 💧Must be resistant to water and moisture
- 🌡️Must withstand hot and cold weather conditions
- 🔒Must seal tightly with a self-adhesive closure
- ✨Must provide an opaque (black, silver-metallic or white) light-blocking surface
- 🪞Must be laminated so the layers do not separate
- 🧪Must be resistant to chemicals
- 🏷️Must provide a surface suitable for label application
- 💰Must offer an optimal cost/protection balance