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How to Choose Poly bags, Mailers, and Paper Bags

Start with the right material for the job, then pick the thickness and closure. This guide compares LDPE, HDPE, anti-static, VCI, and paper bags. It also gives a simple sizing formula and a thickness chart from 1.5 mil for small parts to 6 mil for sharp or heavy items. It warns against common mistakes, like storing metal parts in standard poly (use VCI to prevent rust) or overpaying for thickness you don’t need.

Choose the material for the job first, then the thickness and the closure.

Steps

Pick the material. Use LDPE poly for general parts and clean storage, and HDPE for thin, strong bags. Use anti-static bags for electronics, VCI or vapor bags for metal parts that can rust, and paper bags when recyclability matters.
Pick the thickness, measured in mils (1 mil = 0.001″). Thicker bags resist punctures but cost more.
Pick the closure: open top, re-closable zipper, self-seal adhesive, or heat seal.
Size it right. Bag width should equal the product’s width plus its depth, plus about 1″. Length should equal length plus depth, plus about 1″.

Use	Typical thickness
Small, light parts and kitting	1.5–2 mil
General parts and hardware	2–4 mil
Sharp, heavy, or bulk items	4–6 mil
Poly mailers for shipping	2.5–3 mil

Common Mistakes

Using standard poly for metal parts in storage, which leads to rust. Use VCI bags.
Overbuying thickness for light items. A 4 mil bag costs about twice as much as a 2 mil bag.
Skipping packing list envelopes, which leads to lost paperwork at receiving.

Call S&S When

You need printed or custom-size bags, military spec bags, or help matching a bag to a part.

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How to Choose Poly bags, Mailers, and Paper Bags

Choose the material for the job first, then the thickness and the closure.

Common Mistakes

Call S&S When

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