RRD has revealed a paper-based mailer with a peel-and-seal strip and instant-bond adhesive – designed for kerbside recyclability, regulatory compliance, and seamless operations on automated lines.
The VersaPac FastTrack Paper Mailer is made from third-party certified paper and is kerbside recyclable across the United States. RRD anticipates that this will prevent the ‘recycling guilt’ of throwing away plastic films.
It replaces silicone-coated poly strips with a peel-and-seal strip made from recyclable paper. Not only is this component expected to prevent contamination in the paper recycling stream; it is also intended to avoid slip hazards and keep packages secure.
The mailer’s flat, non-padded design is also anticipated to minimize void space – a move set to help businesses avoid packaging waste penalties and lower dimensional weight surcharges from carriers.
Additionally, it is designed to remove the weight of plastic from the pack, complying with legislation such as California’s SB54 regulation on plastic reduction.
Brands are encouraged to use the VersaPac FastTrack Paper Mailer as a replacement for mixed-material, hard-to-recycle alternatives that incur higher extended producer responsibility fees, such as paper-and-bubble combinations.
The mailer has been tested for high-velocity environments and offers the necessary tooth for robotic vacuum suctions. Its instant-bond adhesive is set to benefit high-speed fulfilment operations.
“The market for paper mailers has seen explosive growth in recent years, driven by both regulatory pressure and a clear consumer preference for eco-friendly shipping,” explained Craig Lombardi, vice president of Business Development, Integrated Packaging at RRD.
“By leveraging our deep engineering expertise and manufacturing strengths, we’ve developed a solution that bridges the gap between ambitious sustainability goals and high-velocity operational needs. This paper mailer turns recycling from a chore into a subconscious win for our clients and consumers.”
The VersaPac FastTrack Paper Mailer is available in three standard sizes: small (5.5” x 8”), medium (10” x 13”) and large (14” x 15.375”). Custom sizing and six-colour flexographic printing are also available for customized branding.
Customers may also combine the mailer with RRD’s VersaTac Liner-Free shipping labels and VersaTac IQ RFID labels, which are expected to improve the pack’s trackability and reduce waste across the e-commerce supply chain.
In similar news, Antalis previously debuted a recyclable, FSC-certified and expandable mailing bag made by Jiffy. The pack is designed to fit snugly around products, eliminating the need for oversized boxes and unnecessary padding.
Meanwhile, Amazon has joined forces with the Indian Institute of Technology Roorkee to manufacture home-compostable and recyclable mailers from crop residues such as wheat, straw, and bagasse waste. This solution is hoped to reduce plastic consumption, cut carbon emissions, and help farmers profit from side streams.
If you liked this story, you might also enjoy:
The ultimate guide to packaging innovation in 2026
Packaging and Packaging Waste Regulation: what to know in 2026
Everything you need to know about global packaging sustainability regulation
No comments yet