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Expandable Bubble Mailers


The Xpandojacket™ is an expandable, bottom gusset, poly bubble mailer with a moisture resistant triple layered polyethylene exterior. This innovative gusseted mailer eliminates the need for expensive and inconvenient boxes with void fill because it expands to fit and protect larger e-commerce shipments. Available in bright white, or custom printed with your branding, this mailer is perfect for bulky items such as toys, blankets, shoes, handbags and electronic components.

Environmentally Friendly

Xpandojacket mailers are 100% recyclable, made from #2 HDPE. Eliminate the need for corrugated boxes, air filled pillows, packaging peanuts or crumpled kraft paper and stop over packaging. Not only will you decrease DIM weight costs by downsizing to flexible mailers, but you will decrease your total carbon footprint as well. Click here for more information on the recyclability of the Xpandojacket, or use our DIM weight savings calculator to see how much you can save.

How2Recycle logo


PAC Worldwide is proud to be a member of the How2Recycle Label Program. How2Recycle is an on-package recycling label developed by the Sustainable Packaging Coalition, a project of the nonprofit GreenBlue. For more information please visit:

Where to Recycle Your Bubble Mailers

Where to Recycle Your Bubble Mailers

Curbside - Each municipality has different recycling capabilities, so check with your local service to be sure they can recycle #2 plastics before dropping them in your curbside recycling container.

Grocery Stores - Any grocery store that offers plastic bag recycling will accept Xpandojacket mailers. You can look up the locations in your area at

Return to PAC Worldwide - We will recycle your used mailers!


The PACzip™ tear strip enables the mailer to be opened easily by the recipient, without compromising its integrity or the security of its contents in transit. Check out this video to see just how easy PACzip is.

Xpandojacket Dual Peel Seal

Dual Peel and Seal

Dual Peel and Seal mailers allow customers to reseal and reuse the original packaging, for truly hassle free returns. This is ideal for any e-commerce merchant that wants to enhance the customer experience and add value. Reusable packaging reduces waste and is more environmentally friendly.

Stock Expandable Bubble Mailers

Plain white Xpandojacket mailers are available through our convenient stock products program in 2 industry-standard sizes.

Custom Xpandojacket

Custom Expandable Bubble Mailers

Before your customers ever see the product, they will see the branded mailer it came in. Don’t waste that precious space! Put your brand right in your customer’s hands with custom printed bubble mailers. We can print even the most complex designs with our six-color printing process. Create your custom design with our online Build-A-Mailer tool.