At my local post office they have these packages that are used to ship large photos and artwork of various sizes. Inside the package is a corrugated plastic sheet (sort of like the signs you see when local elections come up). It has several different folding perfs to accommodate various sizes of flat objects and then it folds around them like an envelope. The outer bag is a super high strength plastic material that will not rip by hand and has to be cut to remove. I made a trade to a guy early in the year for some stamps and sent him several oversize Romanian sheets in return. this worked perfectly for me and the postage was not too bad as well even with the size and shape of the package. Hope this helps..
I usually mail covers so I start by placing the cover(s) inside a polypropylene sleeve (aka comic book bag). It is then sandwiched between two pieces of chipboard which is a form of cardboard stiffener that can be had at large mailing supply stores. That is then placed inside a mailing envelope and sealed. It is then addressed, stamped, labeled as necessary and off it goes.
I recycle. Stamps are placed in glassine which are taped to a piece of stiff card, usually boxboard cut from some food packaging...cereal box, macaroni and cheese, what ever we've eaten that week. The board is cut to fit in the envelope and sealed. Any open edges taped shut with scotch tape. Then it's off to the post office (always directly at PO, never in a box on the street) and on to its destination. No complaints so far.
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