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United States Mailers 2022-2026

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    Report

  • 196 Pages
  • August 2022
  • Region: United States
  • The Freedonia Group
  • ID: 5661285
Description Jump to:

Demand for mailers is projected to increase 7.2% annually to $3.2 billion in 2026, with advances supported by continued robust levels of e-commerce sales and concomitant gains in the total number of packages shipped. 

In addition, mailers will take share from corrugated boxes in the packaging of shipped parcels due to a number of advantages including:

  • Lighter weight, which reduces shipping costs
  • Lower material use, which aids in source reduction efforts
  • Lower overall packaging costs, as mailers do not require void fill

New Curbside Recyclable Paper Mailers to Experience Strongest Gains

Curbside recyclable paper mailers will grow at the fastest rate of any mailer type, boosted by recent new product development by various companies to improve the sustainability as well as the protective performance of paper mailers. These new mailers feature improved padding materials, making them fully curbside recyclable - unlike mixed material paper bubble mailers - while weighing less than traditional pulp padded mailers and offering comparable or improved protective capabilities. Usage by major e-commerce players such as Amazon will be a major factor in their strong growth.

Health & Personal Care Products to See Largest Gains in Mailer Demand

Though most every application will see healthy growth in mailer demand, health and personal care products are especially ideal for both e-commerce and mailer packaging, as online shopping offers increased selection and price comparison compared to in-store shopping, and these items tend to be small enough to fit snugly in mailers. In addition to large gains stemming from strong growth in e-commerce sales, these products will benefit from the continued popularity of mail-order prescriptions.

Sustainability Remains a Primary Concern & Key Driving Force

Due to its single-use nature and high visibility to consumers, packaging remains at the center of many companies’ efforts regarding sustainability. In an effort to improve sustainability, companies are focusing on more easily recyclable mono-material mailers, such as bubble mailers composed entirely of polyethylene, and padded paper mailers featuring recyclable cushioning. The new curbside recyclable paper mailers in particular will experience strong growth due to their recyclability but also due to improved strength and performance, which allows them to be used for larger packages and with products requiring greater protection.

Table of Contents


1. Executive Summary
2. COVID-19 Pandemic
  • Overview
  • Impact on the Economy
  • Impact on E-Commerce
  • Impact on the Mailers Industry
3. Overview
  • Study Scope
  • Historical Market Trends
  • Materials Trends
  • Demand by Primary Material
  • Plastic Mailers
  • Paper & Paperboard Mailers
  • Mixed Material Mailers
  • Padding & Cushioning Materials
  • Pricing Patterns
  • Foreign Trade
4. Factors Impacting Mailers Demand
  • Retail Sales Outlook
  • Manufacturing Outlook
  • E-Commerce Trends
  • E-Commerce Sales Outlook
  • Right-Sizing & Shipping Container Optimization
  • E-Commerce Ready Packaging
  • Annual Parcels/Packages Shipped
  • Leading Shipping Companies
  • Shipping Containers
  • Packaging Trends
  • Sustainable Packaging
  • Reusable & Returnable Packaging
  • Sustainability Initiatives
  • Recycling & Recycled Content
  • Bioplastics
  • Source Reduction
  • Shipping Costs & Package Weight
  • Competitive Products
  • New Product Development
  • Consumer Preferences
  • Changes to Shopping Habits Due to the COVID-19 Pandemic
  • Frequency of Online Shopping
  • What Consumers Are Ordering Via E-Commerce
  • Prevalence of Boxes in E-Commerce Home Deliveries
  • Online Order Shipping Habits
  • Recycling Awareness & Attitudes Toward Sustainability
  • Views on Safety of Packaging for Online Orders
  • Opening Experience Attitudes
5. Product Types
  • Demand by Type
  • Value Demand
  • Unit Demand
  • Bubble Mailers
  • Scope & Product Description
  • Demand by Type
  • Plastic (Poly) Bubble Mailers
  • Paper Bubble Mailers
  • Other Bubble Mailers
  • Poly Mailers
  • Scope & Product Description
  • Demand by Type
  • Standard Polyethylene Mailers
  • Other Poly Mailers
  • Paper Mailers
  • Scope & Product Description
  • Demand by Type
  • Padded Paper Mailers
  • Kraft Mailing Envelopes (Unpadded)
  • Paperboard Mailers
  • Scope & Product Description
  • Demand Outlook
  • Insulated Mailers (Foil, Cotton, & Foam-Lined)
  • Scope & Product Description
  • Demand Outlook
6. Markets
  • Market Scope
  • Demand by Market
  • E-Commerce
  • Scope & Demand Outlook
  • Retailers
  • Third-Party Fulfillment & Logistics
  • Other E-Commerce Markets
  • Other Markets (Manufacturers, Consumers, & Mail Order)
7. Applications
  • Demand by Application
  • Apparel & Accessories
  • Health & Personal Care
  • Multimedia & Software
  • Toys, Games, & Sporting Goods
  • Other Applications
8. Suppliers & Market Share
  • Industry Composition
  • Market Share
  • List of Industry Participants
9. Appendix
  • Report Details
  • Definitions
  • Abbreviations
  • Freedonia Methodology
  • Study-Specific Methodology
  • Sources
  • Associations & Agencies
  • Related Studies & Reports
  • Macroeconomic Assumptions
  • Economic Environment
  • Demographic Trends
  • Consumer Spending
List of Tables
Table 2-1. Macroeconomic Indicators: 2019 - 2023 (billion 2012 dollars)
Table 2-2. Annual Mailer Demand by Type & Market: 2019 - 2022 (million dollars)
Table 3-1. Annual Mailer Demand: 2011 - 2021 (million units & million dollars)
Table 3-2. Mailer Demand by Material: 2011, 2016, 2021, & 2026 (million dollars)
Table 3-3. Annual Mailer Demand by Material: 2018 - 2025 (million dollars)
Table 3-4. Plastic Mailer Demand by Type & Market: 2011, 2016, 2021, & 2026 (million dollars)
Table 3-5. Annual Plastic Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 3-6. Paper & Paperboard Mailer Demand by Type & Market: 2011, 2016, 2021, & 2026 (million dollars)
Table 3-7. Annual Paper & Paperboard Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 3-8. Mixed Material Mailer Demand by Market: 2011, 2016, 2021, 2026 (million dollars)
Table 3-9. Annual Mixed Material Mailer Demand by Market: 2011, 2016, 2021, 2026 (million dollars)
Table 3-10. Mailer Prices by Type: 2011, 2016, 2021, & 2026 (cents per unit)
Table 3-11. Annual Mailer Prices by Type: 2018 - 2025 (cents per unit)
Table 4-1. Retail Sales: 2011, 2016, 2021, & 2026 (billion dollars)
Table 4-2. Annual Retail Sales: 2018 - 2025 (billion dollars)
Table 4-3. Manufacturers' Shipments: 2011, 2016, 2021, & 2026 (billion dollars)
Table 4-4. Annual Manufacturers' Shipments: 2018 - 2025 (billion dollars)
Table 4-5. E-Commerce Sales by Product Category: 2011, 2016, 2021, & 2026 (billion dollars)
Table 4-6. Annual E-Commerce Sales by Product Category: 2018 - 2025 (billion dollars)
Table 4-7. Annual Packages Shipped by Shipper: 2018 - 2021 (million packages)
Table 4-8. Packages Shipped by Shipping Container: 2011, 2016, 2021, & 2026 (million packages & million dollars)
Table 4-9. Annual Packages Shipped by Shipping Container: 2018 - 2025 (million packages)
Table 4-10. Changes to Shopping Habits Due to COVID-19 Pandemic, 2021 (% respondents)
Table 4-11. “How Often Do You Typically Shop Online?” Online Shopping Habits by Age Group, 2022 (% respondents who shopped online in the last 12 months)
Table 4-12. “How Often Do You Typically Shop Online?” Online Shopping Habits by Rural vs. Urban Setting, 2022 (% respondents who shopped online in the last 1months)
Table 4-13. “How Often Do You Typically Shop Online?” Online Shopping Habits by Household Income Bracket, 2022 (% respondents who shopped online in the last 12 months)
Table 4-14. “What do you shop for online?” Online Shopping Habits by Age Group, 2(% respondents who shopped online in the last 12 months)
Table 4-15. “What do you shop for online?” Online Shopping Habits by Rural vs. UrSetting, 2022 (% respondents who shopped online in the last 12 months
Table 4-16. “What do you shop for online?” Online Shopping Habits by Household Income Bracket, 2022 (% respondents who shopped online in the last 12months)
Table 4-17. “What Share of Your Online Purchases Would You Estimate Arrive in BoxesInstead of Paper or Plastic Mailers?” by Age Group, 2021 (% respondents who shop online for home delivery)
Table 4-18. “What Share of Your Online Purchases Would You Estimate Arrive in BoxeInstead of Paper or Plastic Mailers?” by Rural vs. Urban Setting, 2021 (% respondents who shop online for home delivery)
Table 4-19. “What Share of Your Online Purchases Would You Estimate Arrive in BoxesInstead of Paper or Plastic Mailers?” by Income Bracket, 2021 (% respondents who shop online for home delivery)
Table 4-20. Online Order Shipping Habits, 2022 (% respondents who shopped online in the last 12 months)
Table 4-21. Recycling Awareness & Attitudes Toward Sustainability, 2022 (% respondents who shopped online in the last 12 months)
Table 4-22. Consumer Attitudes about E-Commerce Package Safety, 2022 (% respondents who shopped online in the past 12 months)
Table 5-1. Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-2. Annual Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 5-3. Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million units)
Table 5-4. Annual Mailer Demand by Type: 2018 - 2025 (million units)
Table 5-5. Bubble Mailer Demand by Type & Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-6. Annual Bubble Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 5-7. Plastic Bubble Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-8. Annual Plastic Bubble Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 5-9. Paper Bubble Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-10. Annual Paper Bubble Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 5-11. Other Bubble Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-12. Annual Other Bubble Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 5-13. Poly Mailer Demand by Type & Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-14. Annual Poly Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 5-15. Standard Polyethylene Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-16. Annual Standard Polyethylene Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 5-17. Other Polyethylene Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-18. Annual Other Polyethylene Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 5-19. Paper Mailer Demand by Type & Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-20. Annual Paper Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 5-21. Padded Paper Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-22. Annual Padded Paper Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 5-23. Kraft Mailing Envelope Demand by Market 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-24. Annual Kraft Mailing Envelope Demand by Market: 2018 - 2025 (million dollars)
Table 5-25. Paperboard Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-26. Annual Paperboard Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 5-27. Insulated Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 5-28. Annual Insulated Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 6-1. Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Table 6-2. Annual Mailer Demand by Market: 2018 - 2025 (million dollars)
Table 6-3. E-Commerce Market for Mailers by Type & Market Segment: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 6-4. Annual E-Commerce Market for Mailers by Type: 2018 - 2025 (million dollars)
Table 6-5. E-Commerce Retailer Demand for Mailers by Type: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 6-6. Annual E-Commerce Retailer Demand for Mailers by Type: 2018 - 2025 (million dollars)
Table 6-7. Third-Party Fulfillment & Logistics Demand for Mailers by Type: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 6-8. Annual Third-Party Fulfillment & Logistics Demand for Mailers by Type: 2018 - 2025 (million dollars)
Table 6-9. Other E-Commerce Demand for Mailers by Type: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 6-10. Annual Other E-Commerce Demand for Mailers by Type: 2018 - 2025 (million dollars)
Table 6-11. Other Markets Demand for Mailers by Type: 2011, 2016, 2021, & 2026 (million units & million dollars)
Table 6-12. Annual Other Markets Demand for Mailers by Type: 2018 - 2025 (million dollars)
Table 7-1. Mailer Demand by Application: 2011, 2016, 2021, & 2026 (million dollars)
Table 7-2. Annual Mailer Demand by Application: 2018 - 2025 (million dollars)
Table 7-3. Apparel & Accessories Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Table 7-4. Annual Apparel & Accessories Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 7-5. Health & Personal Care Products Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Table 7-6. Annual Health & Personal Care Products Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 7-7. Multimedia & Software Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Table 7-8. Annual Multimedia & Software Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 7-9. Toys, Games, & Sporting Goods Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Table 7-10. Annual Toys, Games, & Sporting Goods Mailer Demand by Type: 2018 - 2025 (million dollars)
Table 7-11. Mailer Demand for Other Applications by Type: 2011, 2016, 2021, & 2026 (million dollars)
Table 7-12. Annual Mailer Demand for Other Applications by Type: 2018 - 2025 (million dollars)
Table 8-1. Mailer Sales by Company, 2021 (million dollars)
Table 8-2. List of Industry Participants
Table 9-1. Relevant Industry Codes
Table 9-2. Relevant HS Codes
Table 9-3. Abbreviations & Acronyms Used in Study
Table 9-4. Macroeconomic Indicators 2011, 2016, 2021, & 2026 (billion 2012 dollars)
Table 9-5. Population & Households 2011, 2016, 2021, & 2026 (million persons)
Table 9-6. Personal Consumption Expenditures, 2011 - 2026 (billion dollars)

List of Figures
Figure 1-1. US Mailer Market
Figure 2-1. Real GDP by Economic Sector: 2020 - 2023 (% annual change)
Figure 2-2. Annual Mailer Demand by Type: 2019 - 2022 (million dollars)
Figure 3-1. Mailers: Product Examples
Figure 3-2. Annual Mailer Demand: 2001 - 2021 (million dollars)
Figure 3-3. Mailer Demand by Material: 2011, 2016, 2021, & 2026 (million dollars)
Figure 3-4. Plastic Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 3-5. Paper & Paperboard Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 3-6. Mixed Material Mailer Demand: 2011, 2016, 2021, 2026 (million dollars)
Figure 3-7. Mailer Prices by Type: 2011 - 2026 (cents per unit)
Figure 4-1. Comparative Growth: Mailers & Boxes: 2021 - 2026 (million units)
Figure 4-2. “I often select the option to combine my orders into fewer packages.” by Gender, Age Group, Income Bracket, & Rural vs. Urban Setting, 2022 (% respondents who shopped online in the last 12 months)
Figure 4-3. “Most of my online orders are shipped with only one item per package.” by Gender, Age Group, Income Bracket, & Rural vs. Urban Setting, 2022 (% respondents who shopped online in the last 12 months)
Figure 4-4. “I have subscriptions/regularly scheduled delivery for items I order online.” by Gender, Age Group, Income Bracket, & Rural vs. Urban Setting, 2022 (% respondents who shopped online in the last 12 months)
Figure 4-5. “Boxes keep my e-commerce shipments safer than mailers/envelopes/bags.” by Gender, Age Group, Income Bracket, & Rural vs. Urban Setting, 2021 (% of respondents)
Figure 4-6. “A positive ‘unboxing' experience (easy opening, attractive packaging) makes me more likely to buy again from the same online company.” by Gender, Age Group, Income Bracket, & Rural vs. Urban Setting, 2021 (% of respondents)
Figure 5-1. Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-2. Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million units)
Figure 5-3. Bubble Mailer Examples
Figure 5-4. Bubble Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-5. Plastic Bubble Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-6. Paper Bubble Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-7. Other Bubble Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-8. Poly Mailer Examples
Figure 5-9. Poly Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-10. Standard Polyethylene Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-11. Other Polyethylene Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-12. Paper Mailer Examples
Figure 5-13. Paper Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-14. Padded Paper Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-15. Kraft Mailing Envelope Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-16. Paperboard Mailer Examples
Figure 5-17. Paperboard Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 5-18. Insulated Mailer Examples
Figure 5-19. Insulated Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 6-1. Mailer Demand by Market: 2011, 2016, 2021, & 2026 (million dollars)
Figure 6-2. E-Commerce Market for Mailers by Market Segment: 2011, 2016, 2021, & 2026 (million dollars)
Figure 6-3. E-Commerce Retailer Demand for Mailers by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 6-4. Third-Party Fulfillment & Logistics Demand for Mailers by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 6-5. Other E-Commerce Demand for Mailers by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 6-6. Other Markets Demand for Mailers by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 7-1. Mailer Demand by Application: 2011, 2016, 2021, & 2026 (million dollars)
Figure 7-2. Apparel & Accessories Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 7-3. Health & Personal Care Products Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 7-4. Multimedia & Software Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 7-5. Toys, Games, & Sporting Goods Mailer Demand by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 7-6. Mailer Demand for Other Applications by Type: 2011, 2016, 2021, & 2026 (million dollars)
Figure 8-1. US Mailer Market Share by Company: 2021 (billion dollars)
Figure 8-2. US Mailers Market: Leading Supplier, 2021
Figure 8-3. US Mailers Market: Second Leading Supplier, 2021
Figure 8-4. US Mailers Market: Third Leading Supplier, 2021
Figure 8-5. US Mailers Market: Fourth Leading Supplier, 2021

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