RRD has introduced the VersaPac FastTrack Paper Mailer, a paper-based e-commerce mailing solution developed to help brands address packaging-recovery considerations while maintaining the operational performance required in modern fulfilment environments.

The VersaPac FastTrack Paper Mailer is made from third-party certified paper and, according to RRD, is designed for kerbside recycling across the United States. The format replaces the silicone-coated poly release strip used in some self-seal mailers with a paper-based peel-and-seal strip. RRD states that the design is intended to support cleaner paper-recycling streams, reduce loose-strip handling concerns and provide a secure closure for shipped goods.

Designed for e-commerce fulfilment, the flat, non-padded mailer is intended to minimise unnecessary pack volume for appropriate products. This can help brands assess opportunities to reduce void space and manage dimensional-weight exposure, while removing plastic from the mailer construction. The product’s instant-bond adhesive and surface characteristics have also been tested for high-velocity packing environments and robotic vacuum handling, according to RRD.

“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. “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.”

The VersaPac FastTrack Paper Mailer is available in three standard sizes: 5.5 × 8 inches, 10 × 13 inches and 14 × 15.375 inches. RRD also offers custom sizing and up to six-colour flexographic printing, enabling brands to create customised, print-led e-commerce packaging for shipping, promotional messaging and customer communication.

For organisations seeking greater visibility across the e-commerce supply chain, the mailer may be used with RRD’s VersaTac Liner-Free shipping labels and VersaTac IQ RFID labels. RRD positions these options as a way to support package tracking while reducing label-related material waste.

The launch comes as packaging producers face heightened attention to material recovery, producer responsibility and packaging design. In California, SB 54 establishes an extended producer responsibility programme covering specified single-use packaging and food-service ware. In the European Union, the Packaging and Packaging Waste Regulation (PPWR) applies generally from 12 August 2026. 

RRD’s paper mailer is positioned as a packaging-design option for brands responding to these developments. However, brands should evaluate recycling acceptance, material specifications and regulatory requirements in each market where products are placed on the market. The use of a paper mailer alone does not constitute legal compliance with any specific extended producer responsibility or packaging-waste regime.

Source: Packaging Europe