Honeycomb Padded Envelopes

Honeycomb Padded Envelopes All-paper padded mailers. Honeycomb cushioning between two layers of kraft. Two layers of kraft paper with an expanded honeycomb layer between them. The hexagonal structure absorbs shocks and protects the product inside. The standard envelope is all paper, so your customer can put it in paper recycling where it is collected. Only the peel-off strip from the seal goes in general waste. That makes it the go-to mailer for brands that lead with sustainability, and a fast-growing shelf item for packaging retailers. Good for: cosmetics, books, apparel, accessories, small electronics, spare parts, subscription boxes. Shipping heavier or moisture-sensitive goods? See our PE bubble mailers. We keep seven sizes in stock, from 15×21 cm for accessories and cosmetics up to 35×45 cm for folded apparel and larger boxes, each with a 4.5 cm self-seal flap. Between the stock sizes and full custom production, there is a honeycomb envelope for almost anything that fits through a letterbox. Printing runs from a one-color logo to a full-surface design. White envelopes give the cleanest print result; kraft brown carries the natural, recycled look most sustainability-led brands ask for. For how honeycomb envelopes compare with poly and bubble mailers on weight, postage and recycling, see our guide to e-commerce packaging. Why honeycomb Why brands switch to honeycomb envelopes Seven stock sizes, custom sizes and full-design printing on request. All paper in the unlaminated version: recycle with paper where collected. The hexagonal honeycomb layer absorbs shocks by crushing, without plastic. Self-seal strip closes in seconds. No tape gun, no water-activated tape station. Lighter and flatter than a carton, so many sizes can post at large-letter rates. Fan-flat storage: envelopes stack flat and take a fraction of the shelf space of boxes. FSC® certified paper available (FSC® C232146) for brands that need chain-of-custody documentation. At the packing station Pack it in three moves 1. Insert. The product slides straight in. The honeycomb layer is already in place, so there is no extra wrapping step. 2. Peel and press. Pull the liner off the self-seal strip and press the flap. Peel the strip and press to seal: no tape gun, no box to fold. 3. Ship. Flat, light and letterbox-friendly. Many sizes post at large-letter or small-parcel rates instead of box rates, as long as the filled envelope stays inside the thickness limit. One SKU replaces the box, the bubble wrap and the tape for most soft and semi-fragile goods. At a glance Seven stock sizes, ready to ship Size Width x length Flap Fits #1 150 x 210 mm +45 mm Phones, accessories, cosmetics minis #2 180 x 250 mm +45 mm Small electronics, jewelry boxes #3 200 x 280 mm +45 mm Books, A5 goods, spare parts #4 220 x 310 mm +45 mm A4 documents, softcover books #5 250 x 350 mm +45 mm Folded apparel, larger books #6 300 x 400 mm +45 mm Sweaters, multi-item orders #7 350 x 450 mm +45 mm Bulky apparel, larger boxes Sizing a custom envelopeCustom sizesThe rule we spec by: bag width = product width + thickness + 4 cm; bag length = product length + thickness + 2 cm; then add 4.5 cm for the sealing flap. When in doubt, size up. Custom envelopes also get a defined print area on front and back, a 1 cm pressed adhesive edge per side, and rounded corners so the bag does not scratch hands or contents.Range Three cushioning builds The kraft shell stays the same. The cushioning core inside is chosen per product weight and fragility, and every structure can be customized. Standard (ABA)Kraft, one honeycomb cushioning layer, kraft. The everyday build: solid protection at the best cost per unit. Reinforced (ABBA)A double honeycomb cushioning layer between the kraft walls. Higher impact resistance for heavier or edge-sensitive goods. Super-sandwich (ABABA)Alternating kraft and honeycomb in a multi-layer composite. The strongest build, for high-value and fragile mailings.At a glance Specifications Material 2-layer kraft paper + honeycomb paper cushioning (all paper when unlaminated, material code PAP 22) Composition Virgin wood pulp kraft, FSC® certified available (FSC® C232146) Cushioning cores Honeycomb (precision and fragile goods), pressed bubble paper (light goods, cost-effective), corrugated paper (heavy load-bearing) Closure Self-seal hot-melt adhesive strip with release paper; double-strip version for returns (the bag seals twice) Opening options Perforated tear line, punched hole + tear-off strip, or both combined for a clean no-knife opening Bottom construction Flat-bonded bottom; bellows-pleat corner bottom or insertion wide-bottom for extra capacity Waterproof option Optional water-resistant lamination: water beads and rolls off the laminated surface. A laminated envelope is no longer all paper Printing Flexographic, water-based low-VOC inks; any logo or full-surface design Stock sizes #1-#7, 150×210 to 350×450 mm (+45 mm flap), packs of 5/10/20 Custom sizes Yes, see the sizing rule above Returns-friendly by designE-commerce returnsThe double adhesive strip version seals twice: once on the way out, once on the way back. Combined with the reinforced perforated tear line, the customer opens the envelope cleanly and reuses the same bag for the return, no tape and no new packaging.For retailersReseller readyAvailable in every retail format the shelf asks for: bagged packs, printed boxes with product window, belly-band packs, and 30-piece display cartons that go straight from the pallet to the shelf. Sizes, quantities, colors and private-label printing are all customizable.Range Retail pack formats Every format below is produced to your sizes, quantities, colours and logo. Pick one for the shelf, or combine them across a size range. Window BoxKraft carton with a die-cut window so the shopper sees the actual envelope before buying. The front panel carries the size, the self-seal and honeycomb-lining callouts and the recyclability mark. The strongest-selling format in stationery and post-office shops. Belly Band PackA printed paper band wrapped around a stack of envelopes. Almost no packaging material, full-colour branding across the band, and it works in any envelope colour. The format sustainability-led retailers ask for first. Display CartonA 30-piece shelf-ready carton with a tear-open front panel. It ships as a case, opens into a display, and refills the shelf in one move. Printed inside and out, sized per envelope format.Request samples and a benchmark quoteTell us your product dimensions and volumes. We will come back within 24 hours. Request Honeycomb Envelope Pricing Linkedin Or download our full product catalogue