Custom Flat Mylar Bags
Custom flat mylar bags from 100 — three-side-seal foil pouches with no gusset, filled through the open top and heat sealed, in silver, gold, matte or fully printed film, with a zipper and tear notch where the product needs them.
A pouch with no bottom gusset, sealed on three edges and closed on the fourth
- Film
- PET/AL/PE foil laminate or metallized PET/PE; silver, gold, matte black or white, clear front
- Format
- Flat three-side seal, filled and heat sealed through the top
- Options
- Zipper, tear notch, hang hole, rounded corners, window
Order online
Order flat mylar bags
Starting from $0.75 per unit
Printed to your artwork or plain, sold in runs of 100 up to 5,000 units per product online. Freight to the US, UK, Canada and Australia is inside the price.
How an online order runs
- Add the units you needThen check out with your delivery address. Add other products to the same order on the way.
- A digital proof comes backLaid on the dieline, before anything prints. Change it as often as you need.
- Pay once you approve itPay by PayPal invoice or bank transfer after you approve your digital proof, or cash on delivery in the US and Canada.
- We make it and ship it deliveredYour delivery date is confirmed with the proof, against the spec and your fill date. Freight and customs are handled on the way to you.
Another size, board or finish, or more than 5,000 units? Send the spec for a price instead. Freight by market and our terms cover delivery and remakes.
Get a price for Flat Mylar Bags
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Where a flat pouch beats a stand-up one
If the pouch has to stand by itself on a shelf, it needs a bottom gusset; that is a different bag, and our gusseted mylar bags that stand up cover it.
| Single servings and samples | Thin enough to drop into an order or tape to a card |
|---|---|
| Product packed inside a carton | The box does the standing; the pouch only has to protect |
| Hanging retail | A hang hole above the seal and the pouch faces forward on a peg |
| Flat goods | Sheet masks, wipes, patches and powders spread in a thin layer |
| Long-term storage in bulk | Flat bags stack in a bin with no wasted space between them |
Three seals, one fill opening
The bag arrives sealed on both sides and the bottom. You fill it through the open top and close it with a heat sealer: an impulse sealer on a bench for a few hundred a day, a band sealer for more. Leave about half an inch of clean film above the product so the seal jaws close on film, not on powder or crumbs, which is the most common reason a seal leaks.
A zipper, if you add one, sits below that top seal. The customer tears the notch, opens the zipper and can reseal it; the heat seal is what makes the pack tamper evident until then.
Silver, gold, matte or printed film
- Silver foil laminate: the classic look, and the strongest light and oxygen barrier.
- Gold: a tinted layer over the metal, gloss or matte, for gift and premium packs.
- Matte black or white: soft-touch surface that hides fingerprints and scuffs.
- Fully printed: the outer layer is reverse printed in color before lamination, so the print sits under the film and does not rub off.
- Clear front, foil back: the product shows on one face while the back keeps out light.
Sizing a flat bag by what goes inside
A flat bag gives up a lot of its face to the seals: roughly 3/8 in on each side and the bottom, and more at the top for the closing seal and zipper. Measure the product, add the seals and the headroom, then add the thickness of the product to both dimensions, because a full flat pouch bulges and pulls its edges in. A 4 × 6 in bag holds a sachet of tea or a sheet mask; a thick fill of the same weight needs the next size up.
Send the product, its weight and how it is filled. We size the pouch around the fill, not the other way round.
Tear notches, hang holes and rounded corners
| Tear notch | Small cut in the side seal so the pouch opens by hand |
|---|---|
| Hang hole | Round or sombrero hole punched in the top seal for pegs |
| Rounded corners | Softer in a pocket and kinder to the inside of a mailer |
| Zipper | Press-to-close track below the top seal for resealing |
| Window | Clear panel in a printed face to show the product |
The film itself, layer by layer
Mylar is the name people use for metallized or foil polyester laminates. A flat pouch is usually PET on the outside for print and strength, a metal layer for the barrier, and a polyethylene inside layer that melts to form the seal. Thicker film resists punctures from sharp or dry product; thinner film is lighter and cheaper in the mail. For the full range of mylar formats and grades see our main collection of mylar bags.
Flat Mylar Bags — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Film
- PET/AL/PE foil laminate or metallized PET/PE; silver, gold, matte black or white, clear front
- Format
- Flat three-side seal, filled and heat sealed through the top
- Options
- Zipper, tear notch, hang hole, rounded corners, window
- Reverse printed in full color under the outer film, or plain foil with a label
- Sizes
- From about 2 × 3 in sample sachets to 10 × 14 in flat packs; custom sizes
- Minimum
- 100 pouches per size and design
On every job
- Print process
- Flexo in up to ten colors on the outer film, or digital for short runs and changing artwork.
- Color
- A white underprint carries normal color on metalized or clear film. Without it, every color takes on what is beneath it.
- Tolerance
- Bag width plus or minus 2 mm, length plus or minus 3 mm. Film stretches, so a barcode is verified on a filled bag.
- Tooling
- Print plates or cylinders per design, kept. There is no cutting die — the bag is formed and sealed rather than cut.
- Food contact
- A food-grade sealing layer against the product, with the inks trapped between layers rather than on the food face.
- Sustainability
- Mono-material PE or PP where the shelf life allows, which recycles as a soft plastic. A foil laminate does not.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build flat mylar bags on
A flexible pack is a stack of films laminated together, and the middle layer is the barrier. The structure is chosen from the shelf life you need and what you want to be able to say about recycling.
PET / PE
A printable outer and a sealing inner. Moisture barrier, modest oxygen barrier. The everyday laminate for dry goods sold quickly.
2-ply, 70–110 micronPET / AL / PE
Aluminum foil in the middle: the strongest barrier against light, oxygen and moisture. Coffee, supplements, anything with a long shelf life.
3-ply, 90–130 micronMetalized PET
A vapor-deposited metal layer. Bright, lighter and cheaper than foil, with a weaker barrier. Most silver and gold bags are this.
2–3 plyMono-material PE
Every layer polyethylene, so the bag recycles as a soft plastic. Less barrier and a slightly softer hand; the sustainable choice where shelf life allows.
100–130 micronMono-material PP
Stiffer and clearer than PE, with better heat resistance. Suits a stand-up pouch that has to hold its shape on a shelf.
90–120 micronKraft-paper laminate
A paper outer over a film barrier. The natural look with a real barrier behind it; the paper takes only a matte, flat print.
Paper 60–80gsm + filmCompostable film
PLA and cellulose structures certified for industrial compost. Lower barrier, higher cost, and no home-compost claim unless the certificate says so.
60–90 micronLDPE mailer film
Co-extruded opaque film for shipping bags: tear- and puncture-resistant, weatherproof, and recyclable where soft plastics are collected.
60–80 micronNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Film is finished in the lacquer and the ink, not with a laminate.
Matte lacquer
A soft, non-reflective face. Hides handling marks and the most-used finish on a premium pouch.
Gloss lacquer
Wet-looking color. Reads cheaper on some categories and exactly right on confectionery.
Spot matte on gloss
A matte shape on a gloss field, or the reverse. The film equivalent of spot UV.
Metalized effects
Print over the metal layer so a color picks up the shimmer, or lay white under it for a normal color.
Registered emboss
A raised texture pressed into the film. Rare, expensive, and unmistakable in the hand.
Kraft-paper face
A paper outer laminated to the barrier. Matte and flat by nature; no varnish needed.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a pouch by what goes in it, not by a bag size: flat mylar bags
Film packs are specified by fill, not by dimensions. Two products of the same weight can need very different bags, because density decides volume — whole coffee beans take far more room than the same weight of powder.
- Fill weight and density
- Give us both, or send the product. We size from the volume it actually occupies, settled.
- Lay-flat width
- Half the circumference of the finished bag. It is the number a converter works to, and we calculate it from your product.
- Headspace
- Enough film above the fill to seal cleanly and for the bag to stand. Too little and the seal traps product; too much and the pack looks underfilled.
- Gusset
- Bottom gusset depth sets how the bag stands; side gussets add volume without width. Both are chosen from the shelf, not the fill.
- Seal width
- 5–8 mm. Wider on liquids and creams, which contaminate a seal, and on anything that will be posted.
- Sample fill
- A plain bag at the finished size, filled from your line, is the only reliable check before print.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Spec your Flat Mylar Bags
Pick a shape, type a size, choose a film and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about flat mylar bags? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
What is a flat mylar bag?
A barrier pouch made of two layers of foil or metallized film sealed on three edges, with no bottom gusset, so it lies flat rather than standing.
Do flat mylar bags stand up on a shelf?
No. With no folded base they lie flat or hang from a peg. A pouch that must stand needs a bottom gusset.
How do I seal a flat mylar bag after filling it?
With a heat sealer across the open top. An impulse sealer suits small runs; a band sealer suits steady volumes. Keep the seal area clean of product.
Can flat mylar bags have a zipper?
Yes. The zipper sits below the top heat seal, so the pack is tamper evident until opened and resealable after.
How much does a flat mylar bag hold?
Less than a stand-up pouch of the same face size, because the seals take up the edges and a full flat bag bulges. We size it from your product and fill weight.
Can flat mylar bags be printed in color?
Yes. The outer film is reverse printed before lamination, so the color sits under the film and does not scuff off.
Are flat mylar bags good for samples?
They are the usual choice for samples and single servings, because they are thin enough to slip into an order, a card or a mailer.
Do flat mylar bags block light and moisture?
Foil laminate flat bags block light, oxygen and moisture well. A clear-front version trades some of that barrier for showing the product.
Can a flat mylar bag hang on a retail peg?
Yes. A round or sombrero hang hole is punched in the top seal, above the zipper if there is one.
What thickness of film should flat mylar bags use?
Thicker film for sharp, dry or heavy fills that could puncture the pouch; thinner film for light product and lower postage.
Can flat mylar bags have a window?
Yes. A clear panel can be left in a printed face, or the whole front can be clear with a foil back.
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