Custom Gusseted Mylar Bags for Coffee and Loose Foods

Other Products That Suit Gusseted Bags

While coffee is the headline use, gusseted mylar bags work for a wide range of dry goods: Flat-bottomed versions for the same products are covered under custom mylar bags in other formats.

• Loose leaf tea, especially in larger weights for cafés and tea shops.
• Granola, muesli and porridge oats, where the block shape stands well on shelves.
• Dried pasta, rice and pulses for delis and refill shops buying in bulk.
• Pet treats and dry pet food in smaller weights.
• Baking ingredients such as specialist flours, sugar and cocoa.
• Dried herbs, spices and botanicals in bulk weights.

Valves, Tin Ties and Closures

A degassing valve is essential for fresh coffee and optional for most other products. We position it on the front panel, usually in the upper third, and work your design around it so it looks deliberate rather than stuck on.

Tin ties are flexible metal strips laminated into the top of the bag. After the customer cuts the heat seal, they roll the top down and fold the tie ends to keep the bag closed. It is a simple, satisfying closure that customers understand straight away and that keeps the product fresher between uses.

Other options include a tear notch to make opening easier, a hang hole for peg display, and a pull-tab zip for products that are opened many times. Zips work best on flat-bottomed bags, so if resealing is important, we may suggest a slightly different format. Our guide to print and finish options shows matt and gloss on metallised film.

Sizing by Weight

Gusseted bags are usually specified by the weight they hold rather than by dimensions alone, because the same weight of different products takes up very different space. A bag that holds 250 g of dark roasted coffee beans will hold less than that weight of light roasted beans, which are denser, and much more than that weight of loose leaf tea.

The best approach is to fill a sample bag with your product and see how it sits. We can send plain samples in several sizes so you can test fills before ordering printed bags. Leave enough space above the product to make a clean heat seal and to roll the top over at least once with the tin tie.

Common sizes for coffee are 250 g, 500 g and 1 kg, which keeps your pricing simple for retail and wholesale customers.

Think about your packing routine too. Gusseted bags are filled from the top through a fairly narrow opening, so a wide funnel or a scoop with a spout makes the job much quicker. Bags stand up better while filling if they rest in a box or holder of the right width, which keeps the gussets square and gives a neater finished block. The measuring guide for packaging covers fill height and headroom for pouches.

Printing and Finishes

Gusseted mylar bags can be printed in full colour across the front, back and gussets. Digital print suits short runs and several designs, such as different origins or blends, while longer single-design runs may suit other print methods that bring the cost per bag down.

Matt finishes are especially popular for coffee and tea, giving a soft, modern look. Gloss makes colours bright and suits snacks and pet food. A spot gloss or a metallic finish can highlight a logo or illustration. Kraft-look outer layers give a handmade, artisan feel while keeping the mylar barrier inside.

Many roasters print one master bag design and add a sticker or stamp for each coffee's origin and roast date. That way a single print run covers a changing menu of beans.

Roasters selling single-origin coffees often vary only the colour of the tin tie or a small band on the bag, which is a subtle but effective way to tell origins apart. Upload the artwork through the free proof request and we will show it across the gussets.

Fill a Sample Bag With Your Lightest Roast

Weight tells us less than volume, because 250 g of a light roast takes more room than 250 g of a dark one, so ask for plain samples in two or three sizes, fill them with your least dense product to the weight you sell, and check there is room above the beans for a clean seal and one roll of the tin tie. Decide the valve at the same time: every fresh-roasted coffee needs one, most other products do not.

Say how many designs you really need, as many roasters sticker the origin onto one master bag. Send the product, the weights, valve or tin tie, and the artwork, and a custom quote comes back by email within one working day, with low minimums quoted per job. The free proof shows the front, back and gussets with the valve position marked. Production takes 4–7 working days after approval and tracked delivery to UK mainland addresses is free, taking 2–3 working days. Misprinted or damaged bags reported within 10 days are reprinted or refunded. Roasters who prefer a paper look with the same barrier often move to kraft-lined mylar bags for the shelf range.