Why Focus on Mailers? If you’re a small online seller, packaging is one of the most visible and fixable sources of waste in your operations. While shipping boxes get a lot of attention, mailers are often overlooked. But they matter. Mailers (poly, kraft, compostable) are lightweight, high-volume, and used daily across fashion, accessories, health products, stationery, and more. And the data proves their collective impact is massive: The global compostable mailers market is expected to grow at 15.8% CAGR, reaching $5.4B+ by 2033 — driven by eCommerce and sustainability pressure.— DataIntelo 2024 Report Trimming 10 grams of CO₂e per shipment across just 100,000 orders = 1 metric ton of emissions saved.— Ecopackables Sustainability Blog, 2024 Most conventional poly mailers are not recyclable curbside, and nearly 91% of plastic packaging still ends up in landfills or oceans.— EPA, Plastic Waste Data 2023 Small Shops, Big Impact If We Move Together One sustainable mailer won’t change the planet but 1,000 small sellers using better mailers can. Here's how you drive real change: Impact Area Why It Matters Aggregate Demand Shared adoption lowers unit costs and increases supplier investment in sustainable materials. Create New Norms When eco-mailers become the norm, customer expectations shift and competitors follow. Influence Supply Chains Volume adoption pushes carriers and sorters to invest in composting or recycling solutions. Avoid “Greenfluff” A collective, transparent commitment builds credibility. Customers see it’s real, not marketing spin. What Are Your Sustainable Mailer Options? Eco doesn’t mean low-quality. Today’s advanced mailers combine environmental responsibility with performance. Material Benefit Caveat Recycled Poly Mailers (PCR) Made from post-consumer plastic. Reduces virgin material demand. Must be clearly labeled and recyclable in local streams. Paper/Kraft Mailers Compostable, recyclable, lightweight. Great for non-fragile goods. Can lack water resistance. Compostable Bioplastics (PLA, PBAT blends) Industrial composting ready. Low plastic footprint. Requires industrial composting—home compost may not work. Hybrid Reinforced Kraft Paper + biofilm layer. Strong, recyclable, and durable. More complex to manufacture. Your 6-Step Mailer Sustainability Guide This guide will help you reduce your mailer-related emissions in just 30 days. 1. Audit Your Usage Volume of mailers/month Avg. weight per mailer Return rate or customer issues Material type (poly, paper, etc.) Example: 2,000 orders/month × 20g mailer = 40kg packaging/month. 2. Switch to Sustainable Materials Kraft mailers for lightweight products Compostable or recycled poly for apparel or flexible goods Reinforced kraft for heavier items Target: Reduce mailer carbon footprint by 10g or more per shipment. 3. Right-Size Your Mailers Oversized mailers increase carbon per shipment by up to 30%. Use mailers just big enough to fit your product with a snug buffer. 4. Educate Your Customers “This mailer is 100% compostable, dispose in green bin.” “Please reuse or recycle this packaging, let’s reduce waste together.” 🗣 Customers appreciate transparency, and many want to help. 5. Collaborate with Other Sellers Join or create a sustainable seller collective. Bulk-order mailers to reduce cost per unit. Share supplier research and testing results. The more sellers join, the cheaper and easier eco-mailers become. 6. Track and Share Your Impact “We’ve reduced our packaging emissions by 300kg this year.” “All our mailers are now 100% paper-based and home compostable.” 📈 Build customer trust and demonstrate leadership in sustainability. A Look at the Numbers Seller Type Orders/Month Mailer Type Emissions Cut/Year Solo Etsy Seller 500 Kraft ~150 kg CO₂e Shopify Boutique 1,500 Compostable Bioplastic ~450 kg CO₂e Amazon FBA Hybrid 5,000 PCR Recycled Poly ~1,000+ kg CO₂e Multiply this by 1,000 sellers, and you get emissions savings in the hundreds of metric tons annually all without changing a product or shipping carrier. Final Word: The Packaging Revolution Starts with You You're not "just one small business." You’re part of a global ecosystem of independent creators, retailers, and innovators. If each of you makes better choices and you tell your customers why the supply chain will follow. At TerraboardOnline.com, we’re proud to support this movement. If you're ready to transition your business to premium recyclable or compostable mailers, we’re here to help. Let’s turn your small shop into a big driver of sustainable change. Want to switch to recyclable mailers? Contact us to start your sustainable packaging transformation Or call one of our customer service representative at 502-810-1255

A Look Back: The Humble Origins of the Envelope Envelopes, as we know them today, are a far cry from their ancient beginnings. Their roots trace back to early Mesopotamia around 2000 BCE, where clay "envelopes" were molded to protect tablets bearing critical transactions and messages. These weren’t paper, but rather hardened shells used to conceal and verify contents—an early testament to the need for privacy and trust in communication. Fast forward to 17th-century Europe, and paper-based envelopes began appearing, handcrafted and sealed with wax. By the 1800s, thanks to industrialization and the introduction of adhesive gum, envelopes evolved into standardized tools for business, personal correspondence, and mass communication. They weren’t just functional they became part of brand identity, diplomacy, and commerce. The Industrial Boom: Envelopes at Scale As the postal system expanded globally in the 19th and 20th centuries, envelope manufacturing followed suit. Automation allowed manufacturers to produce thousands of envelopes per hour, enabling businesses to scale their direct mail operations and formalize their brand presentation. Envelopes became indispensable tools of global commerce—used by banks, retailers, governments, and manufacturers alike. But with this growth came a new challenge: waste. Billions of envelopes ended up in landfills annually many coated with plastic films, metallic inks, or synthetic adhesives that rendered them non-recyclable. A Shift in Consciousness: The Birth of the Recyclable Envelope By the late 20th century, the environmental movement began influencing the paper industry. Manufacturers faced growing pressure to reduce landfill contributions and improve sustainability across the supply chain. The recyclable envelope was born out of this need—a simple but powerful innovation that swapped plastic liners and petroleum-based adhesives for biodegradable, repulpable materials. Early recyclable envelopes used basic uncoated kraft papers and water-soluble glues. While effective, they lacked the durability and premium feel required by high-performance industries like medical supplies, automotive parts, or business-critical mailings. As a result, adoption was slow—limited mostly to niche green-conscious brands or direct mail initiatives with strict environmental policies. The Modern Era: Innovation Meets Sustainability Today's recyclable envelopes are no longer a compromise. Thanks to advances in material science and engineering, manufacturers can now produce envelopes that are: Tear-resistant and durable Moisture- and tamper-resistant Made from FSC-certified and post-consumer recycled content 100% recyclable without removing parts or labels TerraBoard®—an innovation by Papercone—represents this new generation of packaging solutions. It blends sustainable practices with industrial-grade strength, offering manufacturers and distributors a premium recyclable envelope that protects their products and their brand integrity. TerraBoard's evolution mirrors the broader shift in the industry: sustainability is no longer optional it’s a strategic advantage. In an economy increasingly influenced by ESG standards, regulatory pressure, and consumer demand for eco-conscious brands, recyclable packaging isn’t just good for the planet it’s good for business. Why Recyclable Envelopes Matter More Than Ever For businesses handling sensitive documents, parts, kits, or materials, envelopes are more than just packaging—they’re a first impression and a promise. TerraBoard recyclable envelopes deliver: Environmental Compliance – Helping your business meet sustainability goals without compromising quality. Brand Reputation – Communicating your values to customers who care about packaging waste. Operational Efficiency – Durable materials that reduce damage returns while still being eco-friendly. Future-Readiness – Staying ahead of regulatory changes and supply chain demands. The Future of Envelopes Is Sustainable From clay shells to data-backed, recyclable packaging engineered for modern supply chains, the envelope has come full circle serving both communication and protection, now with a conscience. TerraboardOnline.com is proud to lead this evolution. We believe the future of envelopes isn’t just about what they carry it’s about what they represent. TerraBoard®: Strength You Can Count On. Sustainability You Can Stand Behind.

When packaging becomes part of the experience not just the delivery.   The Challenge: A Mailer With a Mission A forward-thinking brand approached TerraBoard® with an unexpected request:  “Can our packaging do more, maybe even entertain kids when it arrives?” Their idea was simple, yet powerful: create a mailer that could be repurposed into a craft project, giving it a second life beyond the doorstep and making unboxing fun for the whole family. Our Approach: Craft Meets Carton Together, we designed a dual-purpose mailer that delighted customers of all ages. Printed on the inside of the TerraBoard® mailer was a cut-and-fold paper airplane template—ready to assemble once the product inside was removed. This imaginative twist on packaging: Encouraged reuse through interactive design Created a playful, sustainable moment for families Reinforced the brand’s creativity and environmental values Why It Worked Eco-Friendly MaterialsAll TerraBoard® mailers are made from 100% recycled content and are fully curbside recyclable, supporting sustainable practices from production to disposal. Interactive DesignThe airplane pattern was thoughtfully designed to be easy to cut, fold, and enjoy with no instructions needed. Value-Added ExperienceWhat was once just a mailer became part of the customer journey, making the brand more memorable and giving children something fun to look forward to. The Impact: Families, Fun, and a Forward-Thinking Brand Parents appreciated the creative reuse and eco-conscious design Kids loved building their new toy The brand stood out with a mailer that sparked joy, encouraged sustainability, and told a story all on its own The result? A packaging experience that generated buzz, strengthened brand loyalty, and aligned with modern values around waste reduction and customer delight. The Takeaway Packaging isn’t just a container, it’s a conversation.At TerraBoard®, we believe in giving materials a second life. This project proves that even small design choices can have a big impact on customer engagement and sustainability. Want to explore creative ways to elevate your packaging experience? If you're ready to make your customer experience unforgettable, we're here to help. Call our customer service team at 1-502-810-1255 or Submit a contact form

When ordering a branded mailer from TerraBoard®, it will be printed using either lithographic (Litho) or flexographic (Flexo) printing. Several factors determine the print type. Here's a brief overview of each method: Lithographic Printing (Litho): An offset printing method where ink is transferred from a metal plate to a rubber blanket, then applied to the substrate. Litho printing is done on a flat sheet prior to die-cutting and conversion. It delivers high resolution output and is ideal for detailed graphics on high-end mailers. Pros Cons High print quality: Excellent for detailed graphics and fine text Color Consistency: Greater color control and registration   Higher cost: High ink costs and higher labor/production costs       Flexographic Printing (Flexo): A direct printing method using flexible plates and fast-drying inks. Ink is applied directly from the plate to the substrate in a single process, integrated with folding and converting equipment. Flexo is best for simple graphics with two colors or less and large-volume runs. Pros Cons Quick turn time: Because everything is produced in a single process, the turn time is often faster Water Based inks: More environmentally friendly Color limitations: Less precise color control and registration         Decision Criteria: Litho vs. Flexo Criteria Lithographic (Litho) Flexographic (Flexo) Print Quality Superior detail, sharp images Good for bold colors and simple designs Color Complexity Handles complex color builds and graphic detail Limited to spot colors and basic designs Inline Integration Requires separate printing, cutting and converting steps Mailers are printed and converted in one process Cost Efficiency Good for all volumes when high quality print is necessary More economical for large runs Best Use Case Premium mailers with complex graphics Bulk mailers with simple graphics   Additional Decision Factors for Litho vs. Flexo Printing Several operational and design-related factors influence the decision between litho and flexo printing methods: Equipment Compatibility:Certain mailer styles and sizes may require conversion on specific machines that lack flexo capabilities. In such cases, litho printing is required. Order Quantity:Flexo printing is generally used for high-volume production runs. At TerraBoard®, flexo is typically used when the custom order quantity exceeds 10,000 mailers. Print Coverage:Extensive ink coverage, such as flood coating (full coverage) or designs that bleed over seams and edges, requires litho printing. Color Requirements:Litho is required for designs involving more than two colors or complex color builds, as our flexo capabilities are limited to basic two spot colors. Visual and Brand Impact:Litho is used for high-end mailers requiring premium print quality and detailed graphics.  Flexo print is better for cost-effective production of large quantities with simple, bold designs. Selecting between litho and flexo print depends on a range of factors including design complexity, production volume, turnaround time, and budget. By understanding the strengths and limitations of each method, we can work with our customers to make informed choices that align with their branding goals. At TerraBoard®, our team is ready to guide you through this process to ensure the most efficient, cost-effective, and visually impactful solution for your mailer project. Want to Upgrade the Shipping Experience Without Sacrificing Scale? TerraBoard® helps brands create shipping solutions that are high-performance, low-impact, and designed for the modern eCommerce experience. If you're ready to make your customer experience unforgettable, we're here to help. Call our customer service team at 1-502-810-1255 or Submit a contact form  

In today’s fast-moving world of commerce, your packaging strategy can’t afford to be slow, outdated, or offline. That’s why we’re proud to introduce TerraboardOnline.com our new digital hub created to serve both brands and distributors who demand performance, sustainability, and simplicity in their packaging supply chain. Whether you’re scaling a fast-growing DTC brand or managing a national distribution network, TerraboardOnline.com gives you on-demand access to the tools, data, and support you need to make smarter packaging decisions faster. Why We Built This Platform For years, TerraBoard has focused on engineering high-performance, eco-conscious packaging materials that meet the demands of modern logistics and sustainability-minded businesses. But as our customer base grew, we saw the same challenges emerge again and again: Distributors needing faster access to custom specifications Brands looking for reliable information on performance and customization Operational teams wanting more efficient ways to integrate sustainable packaging We listened and we responded with more than just a new website. TerraboardOnline.com is a strategic investment in digital infrastructure that puts our customers first and brings our mission to life in a modern, scalable way. What You Can Expect From TerraboardOnline.com This isn’t just a brochure site. TerraboardOnline.com is designed to function as your digital operations center for all things TerraBoard. Here's what you’ll find: ✅ Product specifications and technical details✅ Educational resources for brands, ops teams, and sustainability leads✅ A direct connection to our support team and distributor programs✅ A growing library of insights and tools to support better packaging decisions Every feature is built to simplify your packaging journey whether you’re exploring a switch to sustainable materials or looking to optimize an existing solution. Built for Distributors. Built for Brands. Built for What’s Next. We designed this platform with two core user groups in mind: For Distributors: You get direct access to the latest product data, marketing support materials, and tools to help your customers adopt TerraBoard solutions confidently and quickly. No guesswork. No bottlenecks. Just scalable support. For Brands: You can now browse product lines, review sustainability stats, understand compatibility with your supply chain, and make informed decisions all before ever picking up the phone. It's self-service that doesn’t sacrifice strategy. Digitizing to Support Long-Term Growth The launch of TerraboardOnline.com is part of our larger commitment to digital enablement and customer-first innovation. In the coming months, we’ll continue building out the platform with: Self-serve distributor and B2B customer portals Sample request automation Carbon footprint calculators and impact reporting A learning center for packaging engineers, ops teams, and sustainability leaders These aren’t nice-to-haves—they’re foundational to our belief that sustainability must be easy to adopt, measure, and scale. Closing the Loop Between Product and Experience Sustainable packaging is no longer a niche it’s an expectation. And while the material inside the mailer matters, so does the experience around it. With TerraboardOnline.com, we’re making that experience smarter, faster, and more accessible for everyone from supply chain managers to brand creatives. Our mission has always been to lead with innovation and integrity. This new digital platform helps us do both while making it easier for you to reduce environmental impact and grow your business responsibly.    

Shipping is no longer the end of the sale—it’s the start of your relationship. Most eCommerce brands treat shipping as a backend logistics function. But today’s leading brands are flipping that script using shipping as a strategic touchpoint that deepens loyalty, boosts retention, and drives repeat purchases. If you're in charge of growth, operations, or experience for an eCommerce brand, it’s time to stop asking, "How fast can we ship?" and start asking, "How does shipping reinforce our brand promise?" The Last Mile Is Your First Impression (Again) Customers don’t separate your product from your packaging—or your brand from their unboxing experience. According to a 2025 Shopify consumer study: 73% of shoppers say the shipping experience influences their decision to buy from a brand again 58% are more likely to share a positive delivery experience on social media 86% consider packaging to be part of the brand Let that sink in: the delivery moment, often viewed as a cost or an afterthought, is the brand for many of your customers. From Utility to Emotion: What Great Shipping Experiences Deliver World-class eCommerce brands understand that great shipping isn't just about speed or tracking. It's about how the experience makes the customer feel: Seen – when the packaging reflects their values (minimal waste, sustainable materials) Respected – when the product arrives safely, securely, and on time Delighted – when opening, feels intentional, not transactional In a world of two-day delivery and infinite choice, what sets you apart isn’t always the product. It’s the moment it arrives. Brands That Are Getting This Very Right Glossier: Known for pink pouches, their packaging has become part of their brand equity. Allbirds: Ships using 90% recycled materials with a minimalist design that communicates their sustainability ethos. Terraboard® partners: Integrate branded, biodegradable packaging with high-performance protection elevating both sustainability and customer satisfaction without sacrificing logistics. These brands aren't spending more they're investing smarter in the most underutilized brand asset in eCommerce: the box. 5 Ways to Transform Shipping into a Brand-Building Experience Here’s how you can start turning your shipping process into a scalable competitive advantage: 1. Design for experience, Not Just Transport It’s not enough for your packaging to be functional. It should feel like an extension of your product. Consider: Frustration-free opening (no scissors required) Interior branding (use print inside the mailer) Easy-to-read instructions or welcome messaging QR codes to personalized landing pages or loyalty programs 2. Make Sustainability Part of the Experience Shipping is where your environmental impact shows up, literally. Use sustainable, recyclable, or compostable materials like TerraBoard® Include a card explaining your sustainability mission Encourage customers to recycle, reuse, or even return packaging 55% of consumers say they’re more loyal to brands that demonstrate sustainability beyond the product itself. 3. Balance Protection with Presentation A cracked product destroys trust regardless of how eco-friendly or beautiful the packaging is. Ensure your packaging solution strikes the right balance between: Durability for global transit Material efficiency to reduce waste Brand-forward design for customer engagement 4. Automate Tracking with Branded Communication Tracking emails are one of the most opened messages in the customer journey. Use that real estate: Add links to “How to Use” guides or videos Showcase customer success stories Offer a referral or loyalty reward Shipping shouldn’t be a black hole it should be a branded content experience. 5. Use Returns as a Trust-Building Moment Returns are not losses—they’re brand equity moments. Make your return experience: Seamless and paperless Aligned with your sustainability ethos Communicative (send proactive updates) This turns potential friction into long-term retention. The ROI of Better Shipping Experiences Turning shipping into a customer experience isn’t just good for warm and fuzzy brand love it’s measurable business impact. A positive shipping and packaging experience increases repeat purchases by up to 45% Brands that optimize the unboxing experience see 30% more referrals Sustainable packaging can reduce return rates by improving perceived product quality Final Thought: Every Mailer Is a Billboard. Every Delivery Is a Decision. Shipping is not a transaction it’s transformation. In a saturated eCommerce world, your packaging and shipping experience may be the most consistent physical interaction your customer has with your brand. Make it count. Want to Upgrade the Shipping Experience Without Sacrificing Scale? TerraBoard® helps brands create shipping solutions that are high-performance, low-impact, and designed for the modern eCommerce experience. If you're ready to make your customer experience unforgettable, we're here to help. Call our customer service team at 1-502-810-1255 or Submit a contact form

Why eco-minded eCommerce leaders must act now or risk being left behind. In today’s global marketplace, packaging is no longer just a logistics function it’s a strategic lever. For eCommerce brands navigating complex customer expectations and global supply chains, sustainable packaging isn’t a trend—it’s a business imperative. If you're a brand owner or eCommerce director looking to grow responsibly, the question is no longer if you should shift to sustainable packaging, but how fast. Sustainability Is Reshaping eCommerce Permanently Consumers today are making purchase decisions not just based on price or quality, but on values. According to a 2024 McKinsey study, 60% of consumers across the U.S. and Europe consider sustainability an important factor in their purchasing decisions, and 74% are willing to pay more for products with sustainable packaging. That’s not sentiment, it’s market demand. On the business side, pressure is coming from both investors and regulators. Over 80 countries now have extended producer responsibility (EPR) laws in effect or in development, requiring brands to manage the environmental impact of their packaging. Companies like Amazon and Walmart are already mandating packaging standards from third-party sellers to align with their net-zero goals. If your packaging strategy doesn’t reflect this shift, you’re not just behind—you’re vulnerable. Where Traditional Packaging Fails in Modern eCommerce Global eCommerce is built on speed, scale, and reach. But most traditional packaging materials weren’t designed for that world. Here’s where they fall short: Waste and Volume: Single-use plastic and non-recyclable fillers are major contributors to global landfill overflow. In fact, eCommerce packaging waste alone is projected to reach 4.5 million tons annually by 2026. Carbon Emissions: Lightweight materials like plastic often have a higher carbon footprint over their lifecycle due to extraction, production, and end-of-life impact. Customer Experience: Consumers now notice what arrives in the box. Over 44% of U.S. consumers say they feel guilty when receiving non-sustainable packaging. Sustainability isn’t just about reducing damage to the planet—it’s about elevating brand trust and operational efficiency. Eye-Opening Trends That eCommerce Leaders Can’t Ignore Biodegradable & Compostable Packaging Is Booming: The global compostable packaging market is expected to surpass $32 billion by 2027, growing at over 17% CAGR. Brands that move early gain both first-mover advantage and supplier priority. Digital + Sustainable = Competitive Moat: Companies integrating eco-friendly packaging with AI-powered supply chain optimization are seeing 25–35% cost reductions and improved margins. Packaging as a Brand Differentiator: More than 52% of Gen Z consumers say a brand’s environmental impact influences their social media sharing behavior. Sustainable packaging isn’t just good for the planet—it’s good for your marketing engine. The New Playbook for Sustainable Packaging Forward-thinking eCommerce leaders are no longer asking whether sustainable packaging is viable they’re building it into their operating systems. Here's what that looks like: Start with Materials That Tell a Story: Use recycled content, biodegradable fibers, or FSC-certified materials that align with your brand’s mission. Products like Terraboard® lead the way here—offering both strength and sustainability without compromise. Design for Efficiency, Not Just Aesthetics: Right-sizing your packaging not only reduces material use but cuts down on shipping emissions and dimensional weight fees. Measure & Communicate Impact: Integrate packaging data into your product lifecycle analytics. Use carbon calculators, and publish your impact metrics. Today’s buyers reward transparency. Close the Loop with Circularity: Partner with recyclers, offer returnable packaging, or implement take-back programs to extend the material lifecycle. Brands Already Leading the Way Patagonia has committed to 100% reusable or home-compostable packaging by 2025. Unilever has reduced its plastic packaging footprint by 20% in 3 years through material innovation. Terraboard’s partners are seeing increased customer satisfaction and measurable brand lift by integrating sustainable packaging into their direct-to-consumer channels. This isn’t just ESG, it’s smart business. Final Word: Sustainability Is a Growth Lever, Not a Cost Center Many eCommerce leaders mistakenly view sustainable packaging as a “cost to absorb.” The reality? It’s a revenue driver, a brand amplifier, and increasingly a requirement. Smart companies are building packaging strategies that scale with their growth ambitions and align with the global direction of commerce. And with material innovation accelerating and regulatory frameworks tightening, the time to act is now. Ready to Future-Proof Your Packaging? TerraBoard® is purpose-built for modern, sustainable eCommerce. If you're ready to elevate your packaging strategy with materials that deliver performance, brand value, and environmental leadership we’d love to talk. Contact us to start your sustainable packaging transformation Or call one of our customer service representative at 502-810-1255