RRD Debuts Paper Mailer to Support Recyclable E-Commerce Packaging

Photo Credit: RRD 

According to company reports, RRD has launched its VersaPac FastTrack Paper Mailer, a paper-based shipping mailer featuring a recyclable paper peel-and-seal tear strip designed for curbside recycling. The company said the product provides an alternative to plastic closures and mixed-material mailers while supporting automated, high-speed fulfillment operations.

The new mailer expands RRD’s packaging portfolio, which includes the Flex Mailer, rigid boxes and corrugated packaging. RRD said the paper-based format can help brands reduce plastic packaging and move away from paper-and-bubble mailers, which can be difficult to recycle and may result in higher extended producer responsibility (EPR) costs.

The VersaPac FastTrack Paper Mailer was developed by RRD’s in-house research and development team. Its construction uses third-party certified paper, while a recyclable paper peel-and-seal strip replaces silicone-coated plastic strips. RRD said the alternative closure is intended to avoid recycling contamination and handling issues associated with some plastic strips.

The mailer is designed for high-volume e-commerce fulfillment. Its flat, non-padded construction reduces empty space in shipments and can help optimise dimensional weight (DIM), potentially lowering carrier surcharges and reducing packaging-related waste.

RRD has also designed the paper surface for automated handling, including robotic vacuum systems used in fulfillment lines. An instant-bond adhesive is intended to allow packages to be sealed without slowing automated packing operations.

The mailer is available in three standard sizes: small at 5.5 by 8 inches, medium at 10 by 13 inches and large at 14 by 15.375 inches. Custom sizing and six-color flexographic printing are also available.

“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,” said Craig Lombardi, Vice President of Business Development, Integrated Packaging at RRD. He said the product was developed to combine material reduction with the performance requirements of high-speed fulfillment.

The VersaPac FastTrack Paper Mailer can be paired with RRD’s VersaTac Liner-Free shipping labels and VersaTac IQ RFID labels. RRD said the combination provides packaging, labelling and tracking capabilities within a broader e-commerce supply chain solution.

The company said the product supports California’s SB 54 plastic reduction requirements by reducing plastic weight and providing an alternative to mixed-material shipping formats.

RRD also reported progress on its own emissions reduction programme, saying it has reduced global Scope 1 and 2 greenhouse gas emissions by more than 18% over the past three years. The company has a 10-year target to reduce emissions across its global operations by 25% through energy-efficiency measures.

Source: RRD

SUNSHINE Spotlight: RRD’s new paper mailer combines curbside-recyclable paper construction, plastic reduction and automated fulfillment performance for e-commerce shipping applications.