Packing supplies: tape, wrap, mailers & void fill
4 min read
Which packing tape, stretch wrap, bubble mailers and void fill you actually need to ship safely — and how to choose each without overbuying.
Packing tape: width, mil and adhesive
For sealing corrugated boxes, 2-inch tape suits most cartons and 3-inch closes heavy or wide boxes in fewer passes. Thickness is measured in mils — around 1.8 mil is a solid everyday tape, heavier mil resists splitting on full boxes. Clear acrylic tape is quiet and consistent; tan hot-melt grabs harder on recycled board. Run one strip along the center seam and one across each end (the H-taping method) for a seal that survives the trip.
Stretch wrap: for pallets and bundles
Stretch (pallet) film bundles multiple boxes or odd-shaped items onto a pallet so they move as one unit. Hand wrap on a small core handles a pallet or two at a time; wider, longer machine-grade rolls are for higher volume. It's not for sealing individual boxes — that's tape's job — but it's what keeps a stacked load from shifting in a truck.
Bubble mailers vs a box
A padded bubble mailer is lighter and cheaper to ship than a box for small, semi-flat, non-fragile items — apparel, books, accessories. Reach for a box when the item is rigid, fragile, or needs to keep its shape. Mailers come in numbered sizes (a #2 fits roughly an 8.5 × 12 inch item); pick the size that holds the item with a little slack, not a lot.
Poly mailers
Poly mailers are lightweight, water-resistant plastic envelopes for soft, unbreakable goods like clothing. They weigh almost nothing, which keeps postage down, and self-seal in a second. Skip them for anything that can be crushed or punctured.
Void fill: paper and bubble
Void fill keeps your product from rattling and absorbs shock. Kraft packing paper is the versatile, recyclable workhorse for wrapping and filling gaps; bubble cushioning wraps fragile faces directly. The goal is a box that doesn't shift when you gently shake it — fill the gaps, cushion the fragile bits, don't overstuff to the point the box bulges.
A starter kit for a small shipper
Most small operations run on a short, repeatable list: one or two box sizes, 2-inch tape, a roll of paper or bubble for cushioning, and mailers for the small flat stuff. Standardize on what your orders actually need, buy your proven items by the case so the per-unit price drops, and reorder before you run out. In the Dallas area we carry the boxes and the supplies on the same truck, so it all arrives together.
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FAQ
What tape should I use to seal shipping boxes?
A 2-inch wide packing tape around 1.8 mil thick handles most cartons; step up to 3-inch for heavy or wide boxes. Clear acrylic is quiet and reliable; tan hot-melt grips recycled board harder. Tape the center seam and both ends.
Should I ship in a bubble mailer or a box?
Use a bubble mailer for small, semi-flat, non-fragile items — it's lighter and cheaper to ship. Use a box for rigid, fragile, or shape-sensitive products.
What is stretch wrap used for?
Stretch (pallet) film bundles multiple boxes or items onto a pallet so they move as a single stable unit. It secures loads for transport; it isn't used to seal individual boxes.
How much void fill do I need?
Enough that the product doesn't shift when you gently shake the closed box. Wrap fragile faces with bubble, fill empty gaps with paper, and avoid overstuffing until the box bulges.