Case Study: Our 5 Most Unique Poly Mailer Projects

We’ve had the good fortune to work with hundreds of customers throughout the years, helping them produce custom poly and kraft mailers to their exact specifications.

And looking back at our portfolio, it got us wondering: if we had to pick the five most unique poly mailer projects we’ve ever done, what would they be?

So, we dived back into our archives to find out.

The Top 5 Unique Poly Mailers We’ve Created for Customers

If you’re wondering what criteria we used to pick these projects, we based it on a few key criteria:

  • Creativity
  • Unique customer goals
  • Utility
  • Appearance

And the five projects we selected run the full spectrum.  

Here they are, in no particular order.

1. Viasox


Viasox is no ordinary sock brand. It’s the maker of the world’s first special diabetic socks. And at the core of everything Viasox does is a commitment to fashion, practicality, and quality.

As an eCommerce business, Viasox has to be strategic in ensuring it creates an unforgettable brand experience for its customers. And they came to us with two challenges:  

  1. They were growing. Fast.
  2. They wanted their mailers to sand out from the crowd.

We were able to overproduce for them and offer additional warehousing space so that they could take releases of supply just in time to fill their orders.

This gave them more flexibility with their own production and processing space and helped them to free up resources.

And as for the design, we created a consistent brand message and colour scheme across their poly mailers and eCommerce boxes.

For even more detail about this project, check out our full case study about Viasox.  

2. Ayylien Clothing

Ayylien Clothing

If you ask us, this was the ultimate project when it came to creating poly mailers that stand out!

Ayylien Clothing sells ultra-unique t-shirts, long sleeves, headwear, headwear, and accessories. Their garments are eye-catching, colourful, and artistic.

So, it was only natural that they wanted their deliveries to pack a punch. On this project, budget was of less concern to them. They were more focused on the outcome.

We created an edge-to-edge full-colour print that gave their mailer project an otherworldly look and feel!



Founded in 2014, Cakeworthy is a fashion label designing unisex streetwear apparel and accessories for anyone with a taste for sprinkling some fun into their wardrobe.

The brand collaborates with some of the world’s top licensors to create Special Edition Collections inspired by the things they love: bright colours, bold prints and graphics, pop culture, 80’s and 90’s nostalgia, and the clothes they always wanted as a kid.

Cakeworthy is all about being different. So, it’s needless to say that they wanted their poly mailers to align with their offering. 

They came to us in search of a black poly mailer with knockout logo printing (including on the flap of the mailer) at a competitive price. We took a 2.5mm white poly and treated it with a black flood-coat print, then laid down the logo colours for a fantastic result.

4. SITTI, a social enterprise


SITTI is a cause, not just a business. In their words, “Sitti is a conscious lifestyle brand committed to the self-reliance of refugee and displaced communities through long-term employment opportunities and skill development training, empowered by an inclusive global economy.” 

The company sells handmade soaps to support its mission. And, with that being said, their goal was to find a mailer product that met a few criteria:  

  1. It needed to display the company’s brand and messaging.
  2. In order to have the largest impact, the company needed a low-cost option.
  3. Soap can’t get wet… so, the mailers had to resist water.

We came up with a single-size poly mailer that fit multiple shipment offerings and drove efficiency through volume. We also utilized a simple one-colour print design on a pure white 2.0mmm poly–a great weather-tight option.

5. Maovic


Maovic is a Quebec-based company that makes pillows for children and adults as well as multifunctional nursing pillows made from buckwheat hulls.

When they reached out to us, Maovic needed a poly mailer that matched the colour of the boxes they were using to create a consistent unboxing experience across all their delivery methods. We produced an ink code to match, then laid down a complete flood coat and made their logo and art the centerpiece of the mailer.

At Northern Specialty Supplies, crafting custom poly mailers is our business. Our in-house packaging design team will work with you to bring your vision to life and deliver high-quality mailers that meet your exact specifications.

Want to learn more about our poly mailer process? Get in touch with us today. Our team is here to help.