Mylar Pouches bags

A mylar pouch is a heat-sealed bag made from laminated barrier film, used to keep dry products fresh from air, light and moisture. TBPB prints custom mylar pouches with no minimum order, and if you bring a written quote for the same specs we will beat it.

What the film is actually made of

Mylar started as a brand name for polyester film, and the word has since become shorthand for any shiny barrier pouch. Most are laminates: an outer printed polyester layer, a middle barrier layer of aluminium foil or metallised film, and an inner polyethylene layer that melts when you heat seal it. Foil gives the strongest barrier against oxygen and light. Metallised film is thinner and more flexible, and it suits products that do not need to last long on a shelf. If shelf life matters to you, tell us, because that decides the structure more than anything else.

Pick the pouch format before you pick the size

A flat pouch sealed on three sides is the simplest build and ships almost flat. It suits sachets, samples and single servings. If the bag needs to stand on a shelf, you want a gusseted bottom, which is the territory of our stand-up pouches. For lightweight items that sit in a retail rack or a mailer, the flat pouches are usually the cleaner choice. Then add the features that fit your use: a press-to-close zipper, a tear notch, a hang hole, a clear window, or a one-way degassing valve for freshly roasted coffee.

Sizing by what goes inside

Pouch size is a volume question, not a weight question. Two powders of the same weight can fill very different amounts of space, so a size chart based on ounces is only a rough guide. The reliable method is to fill a test bag or a similar container with your actual product, measure its width and height when settled, and add headspace at the top for the heat seal and any zipper. Order a single sample size first. With no minimum order, testing the fit costs you almost nothing compared with printing a thousand bags that run short.

Print, finish and where mylar is the wrong call

We print your artwork in full colour, with Pantone matching available for brand colours. You can choose a glossy surface for punchy colour, a matte surface for a softer look, or a clear window to show the product. Mylar is excellent for dry goods, but it is a poor fit for sharp or heavy contents that can puncture the film, and not every product belongs in a pouch at all. Fragile or giftable items usually look better in a carton. The mylar bag range covers more specialised formats such as smell-proof mylar bags.

• Laminated polyester, foil or metallised barrier, and polyethylene sealant layers
• Flat, three-side seal or stand-up formats
• Zipper, tear notch, hang hole, window and valve options
• Gloss or matte finish with full-colour printing
• One pouch or many thousands

Send us what goes inside the pouch, the amount you want to fit and your quantity, even if it is just one, and we will specify the size and quote it.

If the contents are food, supplements or anything else regulated, you are responsible for the label copy and for confirming material suitability with your own regulatory adviser. We print the artwork you supply.

Frequently asked questions