Custom Mylar Bags

Closures and Practical Features

A resealable press-to-close zip is the most requested feature, because customers rarely use a whole bag in one go. Tear notches above the zip let the bag be opened cleanly without scissors, as on our tear notch pouches. A hang hole lets retailers display small pouches on pegs. For coffee, a one-way degassing valve lets freshly roasted beans release gas without letting air back in.

Child-resistant zips are available for products that need them, and tamper-evident features show whether a bag has been opened. Rounded corners give a softer, more premium look and stop sharp corners from poking through other packaging.

Each feature adds a little to the cost, so choose the ones your customers will actually use. A snack pouch eaten in one sitting may not need a zip; a large bag of protein powder certainly does.

Think about how the bag will be filled as well as how it will be used. If you fill by hand, a wide opening at the top and a zip set a little lower make scooping easier. If a contract packer fills on a machine, ask them for their preferred format and dimensions before we finalise the design, so the bags run smoothly on their line.

Sizing Mylar Bags by Volume, Not Weight

Two products of the same weight can need very different bag sizes. A hundred grams of dense sugar takes far less space than a hundred grams of puffed snacks or dried herbs, which is why gusseted mylar bags exist for the bulky ones. The best way to size a pouch is to fill a test bag or measure the volume your product occupies, then add headspace for the zip and seal.

For stand-up pouches, the gusset depth matters as much as width and height. A deeper gusset lets the bag stand more steadily and holds more product, but makes the front panel shorter. If you send us your product and target fill weight, we will suggest dimensions that look full on the shelf without straining the seals.

If you sell several fill weights, keep the same width across your range and vary the height. The bags then line up neatly and look like a family.

Remember the bag has to fit wherever it is sold or shipped. Measure the shelf height in the shops you supply, or the mailer box you post in, and make sure a filled pouch fits with room to spare. A bag that is a few millimetres too tall for a standard shelf will be laid flat or left in the stockroom.

Printing on Mylar

Mylar pouches can be printed with full-colour artwork edge to edge. On a metallised film, inks can be printed directly for a shiny, metallic look, or over a white base layer for solid, opaque colours; the print and finish options compared page shows both. Combining the two gives striking effects, such as a logo that shines while the rest of the design is matt.

Matt and gloss finishes can be applied across the whole bag or in selected areas. Soft-touch finishes give a velvety feel that suits premium coffee, skincare and supplements. Kraft-look laminates appeal to artisan and natural brands while keeping the barrier inside.

Plan your artwork around the seals and zip. The top seal, side seals and gusset fold all take some of the printable area, and text placed too close to them may be cut or hidden. The free proof shows these areas clearly.

Short runs are usually printed digitally, which means every flavour or variant can have its own design without extra setup costs. Longer runs of a single design may suit rotogravure printing, which is very consistent across large quantities. We will suggest the most sensible method on your custom quote based on quantity and the number of designs.

Colour on metallised film can look different from the same colour on paper, so if exact brand colours matter, ask for a printed sample before the full run.

Products and Labelling Responsibilities

We print mylar bags for coffee and tea, snacks, dried fruit, nuts, baking ingredients, pet treats, bath salts, supplements and many non-food products such as craft materials and spare parts, with window mylar bags for products that sell on looks. Food-contact grade films are available on request; it is the brand's responsibility to check that the chosen structure suits its product, shelf life and any labelling rules.

Make sure your artwork includes everything your product category requires, such as ingredients, allergens, weight, storage instructions and business details. If those change often, a blank panel for a printed label keeps the bag design flexible.

Fill a Test Bag to the Top and Tell Us How Much Air Was Left

Mylar bags are sized by volume and sealed by the gap above the product, so the most useful thing you can do before ordering is a fill test. Pour your retail weight into a pouch close to the size you have in mind, shake it level and measure the gap to the top seal; a zip needs clear film above it, and a valve must sit above the fill line. Tell us that gap with the weight, and say if the product is dense like sugar or bulky like puffed snacks, which decides between a flat pouch, a stand-up or a gusseted bag.

Send the product, fill weight, style, closures and artwork, and a custom quote arrives by email within one working day, from £0.25 per bag, minimums low and quoted per job. Food-contact grade films are available on request; checking the structure suits the product is the brand's responsibility. A free design proof shows the bag flat with seals marked; production runs 4 to 7 working days after approval and free tracked UK mainland delivery takes 2 to 3 working days. Sample sizes go in small flat mylar sachets to the same run.