Custom Mini Mylar Bags
Custom mini mylar bags printed to your artwork from 100 units, sized for a single serving, a sample or a gram. Send the contents and the count per bag; the dieline and price come back the same working day.
Below four inches, the zipper is a quarter of the bag
- Sizes
- 2 × 3 in to 4 × 6 in (51 × 76 mm to 102 × 152 mm)
- Film
- PET / aluminum foil / PE, 3–4 mil; clear front or window optional
- Formats
- Flat three-side seal, flat with zipper, small stand-up at 4 × 6 in
Get a price for Mini 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.
The four small sizes almost everyone orders
Sizes are stated as the outside of the bag. Take 10 mm off the width for the side seals and about 25 mm off the height for the zipper, top seal and tear line before you work out what actually fits.
At the other end, where a bag holds five or ten pounds of dry goods, gallon bags and the mil that matters is the sizing to read.
| 2 × 3 in (51 × 76 mm) | Single dose, one sachet, a 1 g sample — no zipper, tear notch only |
|---|---|
| 3 × 4 in (76 × 102 mm) | 1–3.5 g flower, a few gummies, a tea sample — zipper fits |
| 3.5 × 5 in (89 × 127 mm) | The default mini: 3.5–7 g, small candy, seeds, jewelry |
| 4 × 6 in (102 × 152 mm) | 7–14 g, a snack portion, a card plus a product — hang hole room |
Zipper, tear notch and hang hole compete for the same inch
On a 3 × 4 in bag the zipper track is 6 mm, the seal above it is 8 mm, and a hang hole needs another 8 mm above that. That is 22 mm of a 102 mm bag spent before the contents start. It works, but it means the printed front is more like 60 mm tall than 100.
Under 3 in wide we recommend leaving the zipper off. The bag is a single-use portion at that size and the zipper does not close cleanly on something that narrow.
If you want a hang hole, choose the 4 × 6 in size. On anything smaller it takes the top of your artwork with it.
Filling small bags is a hand job, and the mouth decides the speed
Brands filling a few hundred a week do it by hand. Above a few thousand it is worth a bench-top filler, and the bag width should be chosen to suit its nozzle.
- A 3 in mouth takes a scoop or a funnel, not a pour; count on 4–6 bags a minute by hand.
- Stand-up gussets do not help below 4 × 6 in — the bag is too light to stand when filled.
- A wider, shorter bag (4 × 3 in landscape) fills faster than a tall narrow one for the same volume.
- Pre-opened bags ship flat and clipped; leave the zipper open for filling and close it after.
Print on a face the size of a business card
A 3.5 × 5 in front has less printable area than a coffee sleeve. One mark, one line of type, one color field. Type below 6 pt disappears in the foil texture and anything that has to be read — weight, warnings, batch — goes on the back at 7 pt or larger.
Metallic and matte finishes do more on a small bag than four-color images. A matte black pouch with a single foil-effect logo reads as premium at arm's length; a tiny photograph reads as a mistake. Our guide to choosing a finish sets out which laminations suit which look.
Samples, seeds and single doses
Mini pouches are bought by dispensaries and hemp brands for grams and pre-rolls, by seed companies for named varieties, by tea and coffee roasters for tasting samples, by supplement brands for single servings and by jewelers for pieces that would otherwise sit in a plastic baggie. If the product needs a two-action closure, the child-resistant mylar bag we make is the same bag with a different zipper.
Mini 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
- Sizes
- 2 × 3 in to 4 × 6 in (51 × 76 mm to 102 × 152 mm)
- Film
- PET / aluminum foil / PE, 3–4 mil; clear front or window optional
- Formats
- Flat three-side seal, flat with zipper, small stand-up at 4 × 6 in
- Closure
- Press zipper from 3 in wide, tear notch, heat-seal top
- Hang hole
- Round or sombrero, 4 × 6 in size only
- Up to 8 colors reverse-printed, matte or gloss
- Minimum
- 100 bags
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 metallised 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 mini 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 micronMetallised PET
A vapour-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.
Metallised 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: mini 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 Mini 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 mini 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 the smallest mylar bag you make?
2 × 3 in outside, which gives roughly 40 × 55 mm of usable pocket. Below that the seals are most of the bag.
How much does a 3 × 4 bag hold?
About 1 to 3.5 g of dried flower, a dozen small gummies or a tablespoon of loose tea. It is volume that limits it, not weight.
Can mini bags have a zipper?
From 3 in wide upward, yes. On 2 in wide bags we leave it off because the zipper does not seal reliably that short.
Do they stand up?
Only the 4 × 6 in size, with a bottom gusset and a decent fill. Smaller bags lie flat or hang.
Can I have a window in a mini bag?
Yes, though on a 3.5 × 5 in front a 25 × 35 mm window is about the practical limit if you want any print around it.
Is the film the same as your larger bags?
Slightly thinner. 3–4 mil suits a small bag; the 5 mil used on large storage bags is too stiff to fold and seal neatly at this size.
What is the minimum order?
100 bags per size and design. Most minis are ordered in the low thousands because they are used as samples, but 100 is the floor.
Can I print the back too?
Yes, and you should. The front carries the mark; the back carries weight, ingredients and warnings where they have room to be legible.
Are they child resistant?
Not as standard. Ask for the child-resistant zipper version if the contents require it; the size range is the same.
Can you add a hang hole?
On the 4 × 6 in size, yes. On smaller bags the hole and its reinforcement would take the top of the print.
Do you supply them filled?
No. They arrive flat and empty, bundled in hundreds, ready for your filling and sealing.
Will you send a dieline?
Always, with the quote, showing the seal areas and the zipper so you can see the real print space before you design.
Are mini bags smell proof?
A sealed foil pouch is, until it is opened. After that the zipper holds most of the odor but not all of it; that is true of every zipper bag at any size.
Same range
