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A small mylar bag is a foil barrier pouch under about 4 by 6 inches: a printed PET outer, an aluminum foil or metallized barrier layer, and a food grade PE seal layer, in a size that holds a sample, a single serving, a spice, a tea portion, a piece of jewelry or a bag of small parts. We make them flat, with a zipper and tear notch, or as mini stand up pouches, printed both sides, with no minimum order. The number to start from is the fill: 3 by 4 inches holds about a tablespoon of powder or a few gummies; 4 by 6 holds an ounce of coffee, a single serve protein scoop or a 3.5 gram portion with room to seal.
Small bags do the same barrier job as large ones and cost less to ship and store, which is why sample programs, subscription boxes and trial sizes run on them. The trap is sealing: below 3 inches wide there is barely room for a zipper, a tear notch and a print panel, so the layout has to be planned before the artwork.
Sizes and what they hold
| Size (W x H) | Holds | Typical use | Zipper |
|---|---|---|---|
| 2 x 3 in | 5 to 8 g powder, a few gummies, a ring | samples, jewelry, pills | no; heat seal only |
| 3 x 4 in | 10 to 15 g, a tea portion, a spice sample | single serve, subscription inserts | yes, top |
| 3 x 5 in | 15 to 25 g, 3.5 g herbs with room | samples, trial sizes | yes |
| 4 x 6 in | 1 oz coffee, a protein scoop, 30 g candy | single serve, trial, minis | yes, or mini stand up |
| 4 x 7 in stand up | 40 to 60 g | mini retail pouch | yes, with bottom gusset |
Laminate and thickness
Small bags run 3 to 3.5 mil for the whole laminate; thicker board is wasted on a bag this size and makes it stiff to open. Full aluminum foil gives total opacity and the longest shelf life for coffee, tea, spices and supplements. Metallized PET is lighter and slightly translucent, fine for candy and dry goods. A clear front with a foil back shows the product and keeps most of the barrier. All three seal on the same PE inner layer.
Closures and features
A press to close zipper from 3 inches wide and up; below that the bag is heat sealed and torn open. A tear notch above the zipper. A round or sombrero hang hole in the top seal for peg display. A clear window die-cut into the front panel. Matte, gloss or soft touch finish. For food, a heat seal across the top after filling closes the bag; a small impulse sealer does it by hand for sample runs.
Print and layout
Full color both sides, printed on the outer PET so the ink is under the surface. On a 3 by 4 bag the top three quarters of an inch is seal and zipper, so the print panel is about 3 by 3 inches. We send a dieline with the seal, zipper and window marked so artwork lands where it can be seen. Variable data such as flavor names and lot numbers can be printed as a white panel for a label, or printed in the run with a plate change per version.
In short
What to send us: the fill weight or the item, whether it needs a zipper, whether it hangs, and the number of versions. What you get back: a size with room to seal, a laminate and thickness recommendation, a dieline with the print panel marked, and a physical sample to fill. What it costs you to start: nothing. Free design, free dieline, free samples, no minimum order.
Small mylar bag questions
What is the smallest mylar bag with a zipper?
About 3 inches wide. Below that there is not enough room for a zipper, a tear notch and a seal, so 2 by 3 inch bags are heat sealed and torn open. 3 by 4 is the smallest practical zipper bag.
How much does a 3 by 4 mylar bag hold?
About 10 to 15 grams of powder, a tea portion, a spice sample or a small handful of gummies. A 4 by 6 holds an ounce of coffee, a protein scoop or a 3.5 gram portion with room to seal.
Do small mylar bags keep food fresh?
Yes. The laminate is the same as a full size bag: printed PET, a foil or metallized barrier, and a food grade PE seal layer. Full foil gives the longest shelf life and total opacity; a clear front with a foil back shows the product and keeps most of the barrier.
Can small bags be printed?
Yes, full color both sides. On a 3 by 4 bag the print panel is about 3 by 3 inches once the seal and zipper are allowed for, so we send a dieline with the panel marked before artwork starts.
Is there a minimum order?
No. A few hundred for a sample program or hundreds of thousands for retail. Free design and dieline, free samples, and a printed proof before the run.
No minimum order. One or a full run. Free design and dieline, and a printed proof before production. Free samples so you can fill and seal a sample before you commit. Price match: send a written quote for the same size, board, print and quantity and we will beat it.
Related: circle mylar bags, die cut mylar bags, window mylar bags and all mylar bags.
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