Custom Zipper Mylar Pouches

A custom zipper mylar pouch is a printed foil-laminate bag with a press-to-close zipper above the tear notch, so the customer can open it, take what they need and seal it again. The Best Price Boxes prints these pouches with no minimum order, and if you bring a written quote for the same specs, we beat it.

Why the zipper changes how you spec the pouch

A heat-seal-only bag is fine for a single-use sachet. The moment your product is eaten over days or weeks, the zipper does the real work, because every time it is left open the film barrier stops mattering. So the zipper is the first thing to decide, before artwork and before size. A standard press-to-close track is right for coffee beans, granola, tea, treats and most dry goods. Fine powders such as protein, cocoa or spice blends tend to dust into the track and stop it closing, so ask us about a zipper track suited to powder fills, and tell us what the product is when you send the request.

Position matters too. The zipper sits below the top heat seal, with a tear notch above it. That gap lets the customer tear off the factory seal cleanly without cutting into the zipper itself, and it doubles as a tamper indicator. If you plan to hang the pouch on a retail peg, add a hang hole above the seal and mention it up front.

Sizing a pouch around what it actually holds

Fill volume is what sets pouch size, not product weight. Weight changes with density: a pouch that holds a pound of dense granola will not hold a pound of puffed snacks. The reliable method is to buy or borrow a plain sample pouch in the nearest size, fill it with your real product, and measure it. Leave headspace of roughly one to two inches under the zipper so the bag can close without squeezing the contents out. Stand-up pouches also need a bottom gusset deep enough for the filled bag to sit upright on a shelf; if you are unsure, a flat pouch avoids the problem, though it will lie down on display.

Film, finish and print

Mylar pouches are laminated films, typically a printed outer layer, a metallized or foil barrier layer and a heat-seal inner layer. The barrier is what slows light, oxygen and moisture. Outer finish is your choice: matte for a soft, modern look, gloss for color pop, or a clear window if shoppers need to see the product. Printing is full color, with Pantone matching available when a brand color has to land exactly. A matte pouch with a gloss logo is a common combination and reads well on a shelf.

• Formats: stand-up with bottom gusset, flat (pillow-style) with zipper, and custom sizes
• Closure: press-to-close zipper, with tear notch and optional hang hole
• Finish: matte, gloss, or clear window
• Print: CMYK or Pantone-matched artwork edge to edge
• Quantity: no minimum order, from a single pouch up

When a zipper pouch is the wrong choice

If the product is sold once and finished, such as a single-serve snack or a sample, a plain heat-sealed bag is cheaper to run and simpler to fill. If the pouch must stand on a shelf and your fill is heavy, look at our stand-up pouches and talk to us about gusset depth. If you want a thin, flat package for mail, our flat pouches are the better format. For bulk dry storage rather than retail, mylar food storage bags are built for that job. You can also browse the full mylar bag range.

Food, supplements and other regulated products carry labelling rules, and the contact-material question for your specific fill is yours to settle with your own regulatory adviser. We print the artwork and copy you supply.

Ready to start? Send us your product, the fill amount and a quantity, even one, and we will draw the dieline and quote it.

Frequently asked questions