TemperPack has introduced a recyclable padded mailer aimed at e-commerce shipments, offering an alternative to boxes for a range of products.

The company said the packaging has been developed to improve packing efficiency and protection while increasing usable space inside the mailer.

It uses WaveKraft, a paper-based material that TemperPack said delivers 50% to 80% higher cushioning performance than plastic mailers or standard padded mailers.

The product features a gusseted design that allows it to open more fully and hold its shape during packing, which the company said creates more internal capacity and simplifies handling.

It is intended for shipments of items such as small electronics, cosmetics and speciality foods, where the use of boxes can add dimensional weight, dunnage, inventory demands and extra fulfilment steps.

According to the company, existing padded mailers have not provided sufficient structure or cushioning for those applications, limiting brands' ability to replace boxes.

The mailers passed independent laboratory testing under the ISTA 6 Amazon Overbox protocol, which assesses whether packaging can withstand e-commerce distribution.

The company also cited additional drop testing that found WaveKraft mailers achieved 50% to 80% more shock absorption than traditional plastic mailers and other recyclable cushioned formats.

The recyclable padded mailer is rated "widely recyclable" by How2Recycle.

TemperPack said it is made with 50% recycled paper content, with paper sourced from FSC-certified mills.

The product is intended for categories, including apparel, books, cosmetics, personal care, small electronics, and vitamins.

TemperPack co-founder and chief technology officer Charles Vincent said: “E-commerce has outgrown the limitations of legacy packaging formats.

“We engineered this mailer to deliver the protection of a box with the efficiency of an envelope while meeting the recyclability standards brands and consumers increasingly expect.”