Custom Mylar Bags
Custom mylar barrier bags from 100, quoted with the layer structure stated rather than hidden. Zippers, valves, windows and tear notches, sized from your product and fill weight.
What "mylar" is actually buying you
Get a price for 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.
- 8styles in this range, each with its own page and price
- 100unit minimum on every style, printed or plain
- 4markets quoted in the delivery currency
- ±1mmcutting tolerance on folding board, checked on a sample
8 styles in this range
Styles we make in this range
Every one below is written up, priced and dielined. Tap a style to see how it is built.
01See the build →Dual Compartment Custom Mylar Bags
Custom dual compartment mylar bags with two separately sealed sections in one pouch, from 100 units.
02See the build →Gallon Mylar Bags
Custom gallon mylar bags in 5 or 7 mil foil film, printed or plain, from 100 units.
03See the build →Gold Mylar Bags
Custom gold mylar bags sized to your fill weight, with your print over a metallic gold face, from 100.
04See the build →Mil Mylar Bags
Custom mylar bags in 3.5, 5 and 7 mil, from 100 units, with a plain explanation of what the number means
05See the build →Mini Mylar Bags
Custom mini mylar bags printed to your artwork from 100 units, sized for a single serving, a sample or a gram.
06See the build →Mylar Bags For Freeze Drying
Custom mylar bags for freeze-dried food, from 100 units.
07See the build →Mylar Bags for Pet Food
Custom mylar bags for kibble, treats and raw-fed portions, from 100 units.
08See the build →Mylar Bags with Window
Custom mylar bags with a clear window, made to your size and artwork from 100 units.
Side by side
Which mylar bags style fits
| Style | Board | Build | Minimum | |
|---|---|---|---|---|
| Dual Compartment Custom Mylar Bags | Chosen per job | Flat pouch, stand-up with bottom gusset | 100 bags | Open → |
| Gallon Mylar Bags | PET / aluminum foil / PE, 5 mil standard, 7 mil heavy | Flat open-top, flat with zipper, stand-up with bottom gusset | 100 bags | Open → |
| Gold Mylar Bags | VMPET/PE metallized or PET/AL/PE foil laminate; gloss or matte gold | Stand-up, three-side-seal, flat-bottom, child-resistant | 100 bags | Open → |
| Mil Mylar Bags | Chosen per job | Flat, stand-up, side and bottom gusset, zipper, tear notch | 100 bags | Open → |
| Mini Mylar Bags | PET / aluminum foil / PE, 3–4 mil; clear front or window optional | Flat three-side seal, flat with zipper, small stand-up at 4 × 6 in | 100 bags | Open → |
| Mylar Bags For Freeze Drying | Chosen per job | Heat seal; zipper above the seal for the retail version | 100 bags | Open → |
| Mylar Bags for Pet Food | Chosen per job | Stand-up pouch, flat-bottom box pouch, flat heat-seal for raw | 100 bags | Open → |
| Mylar Bags with Window | PET / aluminum foil / PE, 3.5–5 mil, clear PET/EVOH/PE at the window | Flat pouch, stand-up with bottom gusset, three-side seal | 100 bags | Open → |
The layers are the specification
A two-layer bag with no metallised middle looks identical and blocks almost no oxygen. If shelf life is the reason you are buying a barrier bag, the middle layer is the thing you are actually paying for, and it is the one a spec sheet often omits.
| PET outer | Takes the print, resists puncture |
|---|---|
| Metallised or foil middle | The actual oxygen and light barrier |
| PE inner | Seals to itself under heat; food contact layer |
Ask any supplier for the layer structure, not the thickness. Thickness without structure tells you nothing about barrier.
Choosing the shape
- Stand-up with a gusset. Sits on a shelf, needs headspace to stand — do not size it tight.
- Flat pouch. Cheapest per unit, best for thin or single-serve contents.
- Side-gusset. Coffee's default; holds a block shape and takes a valve neatly.
- Quad seal. Four printable panels and the best shelf presence, at the highest price.
Fittings that earn their cost
A zipper roughly doubles the number of times a customer opens the bag, which is worth it for anything used over weeks and wasted on a single-serve. A degassing valve is essential for fresh coffee and pointless for anything else — see our notes on valves and freshness for when it matters.
A tear notch costs almost nothing and is the difference between opening a bag and attacking it. Specify one on anything without a zipper.
Printing on film is not printing on board
Film prints by rotogravure or digitally. Rotogravure gives superb solid color and needs a cylinder per color, so it is expensive at low volume and excellent above a few thousand. Digital has no tooling and slightly softer solids, which is why almost every 100-unit run is digital.
Matte finishes on film show fingerprints far more than on board. If the bag will be handled in a shop, a soft-touch matte with a gloss spot wears better than an all-over matte.
Across the range
What every mylar bags job runs on
Boards
- Natural kraft
- White SBS
- E and B flute
- Wrapped grayboard
- Food-grade board
- Recycled content
Chosen from what goes in the box and how far it travels. Our notes on recyclable and compostable stocks say which claims each board can carry.
Finishes
- Matte
- Gloss
- Soft-touch
- Foil
- Emboss
- Spot UV
- Kraft
- Textured
Each one is a decision about light on a shelf — the specialty finishes range shows them on real boxes.
Artwork
- Vector PDF or AI, fonts outlined
- 3 mm bleed, 4 mm safe area
- CMYK; a spot color where a match must hold
- Proof on the dieline before press
Files not set up that way are fine — see the guide to preparing print files.
Interactive · five steps · no sign-up
Spec your 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 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.
Is a thicker bag a better barrier?
No. Barrier comes from the metallised or foil layer, not from total thickness. A thin three-layer bag beats a thick two-layer one.
What layer structure will I get?
We quote the layer count on every job. Ask any supplier for the structure rather than the thickness — thickness alone tells you nothing.
What is the minimum order?
100 bags, printed to your artwork.
Are mylar bags recyclable?
Multi-layer laminates are not, in a normal stream. Mono-material recyclable films exist, cost more and give up a little barrier — we quote both.
Do I need a degassing valve?
Only for coffee roasted within the last few days. On anything else it is a deliberate hole in your barrier.
What size bag for 250 g of coffee?
Typically around 130 × 210 mm with an 80 mm gusset, but bean density and grind change it. Send the weight and we will size it.
Is a zipper worth it?
For anything used over weeks, yes. On a single-serve pack it is cost with no benefit.
Can I have a window?
Yes, die-cut with a clear panel. Every window is a gap in the barrier, so keep it to what the product needs.
Digital or rotogravure printing?
Digital below a few thousand — no tooling. Rotogravure above it, with better solids and a cylinder per color.
Are they food safe?
The inner sealing layer is food-grade as standard on every food job.
Is a thicker bag a better barrier?
Not necessarily. Barrier comes from the metallised or foil layer, not from total thickness. A thin three-layer bag outperforms a thick two-layer one.
Can mylar bags be recycled?
Multi-layer laminates are not recyclable in a normal stream. Mono-material recyclable films exist and cost more, with a slightly weaker barrier. We will quote both if it matters.
Do I need a valve?
Only for coffee roasted within the last few days, which off-gasses. On anything else it is a hole in your barrier.
What size bag for 250 g of coffee?
Typically around 130 × 210 mm with an 80 mm gusset, but it depends on bean density and grind. Send the weight and we will size it.
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