Custom Mylar Ziplock Bags That Reseal

Products That Suit Resealable Mylar

Anything dry, used in portions and sensitive to air is a natural fit. Coffee roasters use them for ground and whole bean coffee. Snack brands use them for crisps, nuts and dried fruit. Tea blenders use them for loose leaf. Health food makers pack powders, seeds and granola. Outside food, they work for bath salts, potting mixes, dog treats and craft materials that need to stay dry. Roasters who prefer a fold-over closure to a zip use tin-tie coffee bags with a fold-over top for the same beans.

• Coffee beans and ground coffee
• Nuts, dried fruit and trail mixes
• Loose leaf tea and herbal blends
• Protein powders, seeds and granola
• Pet treats and chews
• Bath salts and soaks
• Craft supplies and small hardware

Bag Shapes and Features

Stand-up pouches have a folded gusset in the base that opens out so the bag stands on a shelf, which is the most popular style for retail. Flat pouches are simpler and lie flat, suiting samples, single portions and products sold from hooks. Side gusset bags are taller and slimmer, common for coffee.

Extras add function. A clear window shows the product inside, though it reduces the light barrier in that area. A hang hole lets the bag hang on a retail peg. A one-way degassing valve is essential for freshly roasted coffee, which releases gas for days after roasting. Rounded corners give a softer look and avoid sharp points in a bag or pocket. Each feature is drawn on the free proof shown on the pouch outline so you can see where a window or valve sits against the artwork.

Sizing a Ziplock Pouch

Size a pouch by its fill weight and the bulk of the product rather than by weight alone. A light, bulky product such as crisps or puffed snacks needs a much larger bag than the same weight of sugar or coffee. The easiest way to check is to fill a sample bag of a known size, or a similar bag you already have, and see where the product level sits relative to the zip.

Leave space above the product for the zip and the top seal, typically a few centimetres, so the bag can be closed without trapping product in the tracks. We can send a size guide and suggest a fit when you tell us your product and fill weight.

Think about the shelf too. A stand-up pouch has to be wide enough at the base to stay upright when half empty, or it slumps and falls over in a cupboard. Gusset depth makes a big difference here: a slightly deeper gusset on a tall bag keeps it standing long after the first portion has been used. If the bag will sit in a display crate or a basket rather than on a shelf, a flatter pouch may be more practical. The fill-and-measure method in our guide to measuring for packaging applies to pouches as well as boxes.

Print and Finishes

Mylar bags can be printed with full colour designs that wrap from front to back and across the gusset. Matt finishes give a soft, modern look and reduce glare on a shelf. Gloss makes colours pop. Spot gloss on matt highlights a logo or product name. Metallic effects come naturally from the foil layer and can be left to shine through in parts of the design.

Leave room on the back for ingredients, batch codes and a barcode, and keep these on a plain, light area so they are easy to read. If you sell several flavours, a shared layout with a colour change per flavour keeps the range tidy and lowers design work.

A matt kraft-look outer also suits natural brands. Matt and gloss films are compared across our printed bags and pouches so a pouch and a paper bag from the same brand can match.

Fill a Sample Pouch to the Zip, Then Weigh It

Mylar pouches are sized by bulk, and bulk is easy to misjudge from a weight alone. Pour the portion you intend to sell into a plain pouch or a freezer bag of the candidate size and see where it reaches; the product should stop at least 30 mm below the zip so the top seal and the zip both close over empty film. If it reaches higher, go up a size, not thicker. Then settle the barrier: metallised film for snacks and tea, full foil for coffee with a valve, and a window only where light will not hurt the contents. Biscuit and cookie makers usually size from the cookie mylar bags with a window panel instead.

Prepare each flavour as a separate artwork file with the barcode on a light area of the back. Email the fill weight, pouch style, barrier, features and number of designs with the quantity, and a custom quote comes back within one working day, followed by a free design proof. Pouches are made in 4 to 7 working days after approval and delivered free and tracked on the UK mainland in 2 to 3 days. Pouches with faulty zips or print reported within 10 days are replaced or refunded.