Honeycomb Padded Envelopes
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 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.
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.
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 |
Three cushioning builds
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 |
Retail pack formats
