RRD has launched the VersaPac FastTrack Paper Mailer, a new addition to its packaging portfolio designed to support brands in reducing plastic use and minimising packaging waste, while enabling kerbside recycling.
A Sustainable Alternative to Mixed-Material Formats
The VersaPac FastTrack Paper Mailer features a paper peel-and-seal strip and is purpose-built for kerbside recycling. According to RRD, the product directly addresses the growing industry challenge posed by mixed-material formats such as paper-and-bubble mailers, which are significantly harder to recycle and are increasingly likely to attract higher extended producer responsibility charges.
The new paper mailer is also fully aligned with California’s SB54 plastic reduction legislation, one of the most stringent packaging regulations currently in effect in the United States. This compliance positions the product as a forward-compatible solution for brands operating in regulated markets.
Developed In-House by RRD’s R&D Team
The mailer was developed entirely by RRD’s internal research and development team. A key design decision was the use of a recyclable paper closure in place of silicone-coated poly strips. The company noted that such poly strips are a known source of recycling contamination and can also create slip hazards in operational environments.
The flat, non-padded construction of the mailer is intended to reduce empty space within shipments, which may help brands lower dimensional weight surcharges and steer clear of anti-waste packaging penalties — both increasingly pressing concerns for e-commerce and fulfilment operations.
Built for High-Velocity Fulfilment Environments
RRD has engineered the paper mailer with practical fulfilment demands in mind. The product has been tested specifically for use in fulfilment settings and is designed to be compatible with robotic vacuum systems. The adhesive used in the closure has been formulated to bond quickly during the packing process, minimising disruption to high-speed operational workflows.
Integration with RRD’s Broader Packaging Portfolio
The VersaPac FastTrack Paper Mailer sits within a wider and complementary packaging range that includes the Flex Mailer, rigid boxes and corrugated packaging solutions. Additionally, the mailer is compatible with RRD’s VersaTac Liner-Free shipping labels and VersaTac IQ RFID labels, offering brands an integrated approach to sustainable packaging and logistics management.
Industry Momentum Behind Eco-Friendly Shipping
Craig Lombardi, Vice-President of Business Development, Integrated Packaging at RRD, commented on the product launch: “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. 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 reflects the broader industry shift toward sustainable packaging formats that meet both regulatory requirements and the practical demands of modern fulfilment operations. With plastic reduction mandates gaining traction across multiple jurisdictions, RRD’s latest offering provides brands with a compliant, operationally efficient, and genuinely recyclable shipping solution.
