Urgent Custom Boxes

Free Design Support on All Custom Boxes & Packaging Orders
Free Design Support on All Custom Boxes & Packaging Orders
Free Design Support on All Custom Boxes & Packaging Orders
Free Design Support on All Custom Boxes & Packaging Orders
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Custom Mylar Bags
FREE US SHIPPINGQUOTE IN 24 HOURSMOQ 500 PER DESIGNFREE DESIGN + 3D PROOF
60+ STYLES / PRINTED TO SPEC

Custom Mylar Bags Printed With Your Brand, Built to Your Barrier Spec

Custom Mylar bags protect coffee, snacks, supplements, dried food, pet treats and regulated products inside a printed, heat-sealed barrier laminate. Urgent Custom Boxes offers more than 60 Mylar bag and pouch styles, from 1 gram sachets to bulk storage bags, in stand-up, flat, gusset, die-cut, spout and child-resistant formats.

Custom Mylar bags are printed pouches laminated from BoPET (biaxially oriented polyethylene terephthalate) film, an aluminum foil or metallized barrier, and a polyethylene sealant. UCB prices start at $0.10 per unit with a 500-unit minimum per design, production takes 2 to 3 business days after proof approval, and shipping takes 4 to 5 business days, with free design support and free shipping on every order.

3.5 TO 7 MIL OTR BELOW 0.1 CC/M²/DAY CR 16 CFR 1700.20 FDA 21 CFR 177.1520
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Free design support Free 3D proof Sample on request
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$0.10From, per unit
500MOQ per design
2-3 daysProduction
4-5 daysFree US shipping
24 hrsQuote turnaround
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Custom Mylar Bag Styles

MOQ 500 per design / prices per unit

16 CFR 1700.20Child-Resistant Mylar BagsMOQ 500 / CR ZIPPER LOCKFrom $0.24 / unit16 CFR 1700.20Smell-Proof Mylar BagsMOQ 500 / FOIL CORE + HEAT SEALFrom $0.30 / unitWindow Mylar BagsMOQ 500 / FOIL BACK + WINDOWFrom $0.36 / unit16 CFR 1700.203.5 Gram Mylar BagsMOQ 500 / 4 X 5 INFrom $0.26 / unit16 CFR 1700.207 Gram Mylar BagsMOQ 500 / 4 X 6 INFrom $0.33 / unit16 CFR 1700.201 Ounce Mylar BagsMOQ 500 / 6 X 9 INFrom $0.40 / unit

Showing 61 of 61 styles

WATCH / 1:53

How Custom Mylar Bags Are Built, Certified and Printed

Layers, thickness, compliance and print methods explained in under 2 minutes, with the price and turnaround numbers most suppliers keep off their pages.

  1. 0:17What Mylar bags are made of
  2. 0:31Thickness in mil
  3. 0:55Child-resistant, smell-proof, food-safe
  4. 1:09Digital vs rotogravure
  5. 1:21Price, MOQ and turnaround
01 / MATERIAL

What Are Custom Mylar Bags Made Of, and How Well Do They Block Oxygen?

Custom Mylar bags are made of 3 or 4 bonded layers: a printed PET outer film, an aluminum foil or metallized PET barrier, and a polyethylene sealant that touches the product. The barrier layer decides shelf life, and a foil core blocks 5 to 20 times more oxygen than metallized PET.

Each layer has one job. The PET outer film carries reverse-printed artwork, so ink sits between layers and does not scuff. The barrier core blocks oxygen, water vapor, UV light and odor. The PE sealant melts at the jaws of a heat sealer and forms the airtight seam. A kraft paper outer layer adds a natural look without changing the barrier inside.

Mylar is the registered trademark of DuPont Teijin Films for its BoPET film, and US buyers use "Mylar bag" for any foil or metallized barrier pouch. Wall thickness runs from 3.5 mil to 7 mil, where 1 mil equals 0.001 inch (25.4 microns). A foil-core laminate blocks 100% of light and holds oxygen transmission below 0.1 cc/m²/day. The PET outer film falls under FDA 21 CFR 177.1630, and the polyethylene food-contact sealant falls under FDA 21 CFR 177.1520.

OTR is tested under ASTM D3985 and MVTR under ASTM F1249. Lower numbers mean better protection.

PET outer filmPRINT SURFACE / 21 CFR 177.1630
Aluminum foil barrier100% LIGHT BLOCK / OTR <0.1
PE sealantFOOD CONTACT / 21 CFR 177.1520
LaminateOTR cc/m²/dayMVTR g/m²/dayLight blockBest fitProduct
PET / AL foil / PEBelow 0.1Below 0.1100%12+ months: coffee, dried food, long-term storageAluminum foil Mylar bags
Kraft / PET / AL / PEBelow 0.1Below 0.1100%12+ months with a paper exteriorKraft Mylar bags
PET / VMPET / PE0.5 to 20.5 to 1.595% to 99%3 to 9 months: snacks, candy, bath productsMetalized Mylar bags
AlOx PET / PE1 to 31 to 3NoneClear pouches that still need an oxygen barrier: granola, nuts, jerkyClear stand-up pouches
PE / EVOH / PE1 to 52 to 5None unless printed opaqueRecyclable mono-material pouches for store drop-off programsStand-up and flat pouches
Clear PET / PE50 to 1203 to 8NoneShort cycles where product visibility sellsClear Mylar bags

Typical industry ranges for laminated structures. Request the spec sheet for your exact build with your quote.

AlOx (aluminum oxide) is a transparent ceramic coating on PET film. It gives a clear pouch a far better oxygen barrier than plain PET, though it stays below foil. A clear front panel with a foil back gives another middle path: custom window Mylar bags keep the product visible while the foil back blocks most light.

Custom Mylar Bag Formats and Sizes

The 9 formats below cover retail shelf, sample, mailer, liquid and storage uses. Every format accepts the same laminates, print methods and finishes, so one brand can run a matched line from sachet to bulk bag.

01Stand-up pouchesStand on a folded bottom gusset for shelf display 02Flat 3-side seal bagsLie flat for samples, mailers and peg hooks 03Side gusset bagsExpand for coffee and bulk fills 04Die-cut bagsFollow a custom outline, from a circle to a product silhouette 05Child-resistant bagsUse a CR zipper tested to 16 CFR 1700.20 06Resealable zipper bagsReclose after every use 07Spout pouchesPour sauces, juices and refills through a capped fitment 08SachetsHold single doses and samples 09Mylar envelopesProtect flat goods such as cards and seeds

More see-through options: clear stand-up pouches and clear front white back Mylar bags.

Hand Filling or an Automatic Pouch Line

Every pouch ships pre-made, open at the top or the bottom, ready for hand filling with an impulse sealer or for a rotary pre-made pouch filler. For machine lines, send the filler model with your quote. We set the zipper position, tear notch height and top seal area to match your jaws, so pouches feed and seal without manual trimming.

SPEC GUIDE

Thickness, Sizes, Bottoms and Finishes

AttributeOptions
LaminatePET / AL foil / PE, PET / VMPET / PE, Kraft / PET / AL / PE, AlOx PET / PE, clear PET / PE, PE / EVOH / PE
BarrierOTR below 0.1 cc/m²/day on foil-core builds (ASTM D3985)
Thickness3.5, 4.5, 5.5 and 7 mil (89 to 178 µm)
FormatsStand-up, flat 3-side seal, side gusset, flat bottom, die-cut, spout, sachet, envelope
Bottom stylesDoyen (DOY), K-seal, plow bottom, flat 3-side seal
ClosuresResealable press-to-close zipper, child-resistant zipper lock (16 CFR 1700.20), tear notch, heat seal
Food contactPE sealant under FDA 21 CFR 177.1520
FinishesMatte, gloss, soft-touch, holographic, metallic, gold, kraft paper
Add-onsClear window, round or sombrero hang hole, rounded corners, one-way degassing valve, spot UV, hot foil
PrintingDigital (short runs, multi-SKU), rotogravure (long runs, up to 10 colors), CMYK plus Pantone
MOQ500 units per design
PriceFrom $0.10 per unit
ProofFree digital proof with flat view and 3D mockup, physical sample on request
Production2 to 3 business days after proof approval
Shipping4 to 5 business days, free
QuoteBy email within 24 hours
02 / PRINTING

Which Printing Method Gives the Best Price on Custom Mylar Bags?

Digital printing gives the best price for short runs and multi-design orders, because it needs no plates or cylinders. Rotogravure gives the lowest per-unit price on long runs of one design, once engraved cylinder costs spread across volume.

Brands launching several flavors, strains or SKUs start digital. Brands with 1 best-selling design move to rotogravure once volume grows. Both methods print to the same Pantone target on every reorder, so a pouch run in spring matches the run in fall.

FactorDigitalRotogravure
Setup costNoneCylinder per color
Best runShort runs, launchesLarge repeat runs
Designs per orderMany, no added setupEach adds cylinders
ColorsCMYK plus whiteUp to 10
PantoneClose CMYK matchExact spot match
Metallic and special inksLimitedFull range
Reorder speedFast, file-basedFast after cylinders exist

Custom Mylar Bag Pricing

Unit price depends on 6 inputs: quantity, bag size, laminate, print method, finish and add-ons. Larger quantities lower the unit price because setup and proofing costs spread across more bags. There are no plate fees on digital orders.

Listed Starting Prices per Unit

MOQ 500 / NO PLATE FEES ON DIGITAL
$0.10Mylar envelopes
$0.12Tear notch pouches
$0.14Sachets, resealable, spout and clear stand-up pouches
$0.15Ziplock and marshmallow bags
$0.161 gram, brown, coffee, clear front white back, dried fruit bags
$0.17Kraft, Halloween and large bags
$0.18-0.20Red, purple, 7 mil, metalized, gusset, vacuum, pet treat, biodegradable
$0.21-0.24Clear, cereal, holographic, granola, die cut, food storage, child-resistant ($0.24)
$0.25-0.26Matte, cookie, jerky, aluminum, gold, sealed, 1 lb, 3.5 gram 4 x 5 in ($0.26)
$0.30Smell-proof Mylar bags
$0.337 gram Mylar bags, 4 x 6 in
$0.36-0.40Window Mylar bags ($0.36), 1 ounce Mylar bags 6 x 9 in ($0.40)
03 / COMPLIANCE

Are Custom Mylar Bags Smell-Proof, Child-Resistant and Food-Safe?

Yes. Foil-core custom Mylar bags are smell-proof once heat sealed, child-resistant when fitted with a CR zipper that passes 16 CFR 1700.20 testing, and food-safe when the product-contact layer meets FDA 21 CFR 177.1520.

16 CFR 1700.20 / ASTM D3475

Child-Resistant

Under the Poison Prevention Packaging Act, at least 85% of children aged 42 to 51 months fail to open the pack before a demonstration and 80% after it, while 90% of adults aged 50 to 70 open and reclose it. ASTM D3475 then classifies the passing package. The CR zipper and bag design carry the certification, so ask for the test report that names the bag style, not only the zipper. See child-resistant Mylar bags.

FOIL CORE + HEAT SEAL

Smell-Proof

Aluminum foil blocks odor molecules from passing through the bag wall. Odor escapes only through an open seam, so 2 controls matter: a foil or high-barrier laminate and a heat seal above the zipper. Smell-proof Mylar bags and heat-sealed tamper-evident Mylar bags use both. The heat seal also shows a buyer at once if the pouch was opened.

FDA 21 CFR 177.1520 / 177.1630

Food-Safe

The polyethylene sealant is the only layer that touches food. FDA 21 CFR 177.1520 covers olefin polymers such as LDPE and LLDPE, and 21 CFR 177.1630 covers PET film. Reverse printing keeps ink off the food-contact surface.

State Cannabis and Hemp Rules

State rules add opacity, warning label and tamper-evident requirements that change by state. Confirm your state rules before artwork approval. Mylar film alone does not make a bag child-resistant.

Recyclability

Foil laminate Mylar bags are not curbside recyclable, because bonded PET, foil and PE layers cannot be separated. A PE / EVOH / PE mono-material pouch qualifies for store drop-off programs that accept plastic film, and biodegradable Mylar bags use plant-based films. Both carry a lower barrier than aluminum foil.

Custom Mylar Bags by Industry

Coffee and tea

Foil gusset or flat-bottom coffee bags with a one-way degassing valve. Fresh-roasted coffee releases carbon dioxide for several days, and the valve vents gas without letting oxygen in.

Snacks, candy and cereal

VMPET stand-up pouches with tear notch and zipper.

Beef jerky bagsDried fruit bags
Long-term food storage

5.5 to 7 mil foil bags sealed with an oxygen absorber sized to the bag volume. Absorbers suit dry foods only, so seal the bag within minutes of opening the absorber pack.

Vacuum sealed Mylar bags
Supplements and protein powder

Foil K-seal stand-up pouches with zipper and hang hole.

Pet treats

Resealable foil pouches.

Licensed cannabis and hemp

Opaque, smell-proof, child-resistant pouches with strain-specific artwork.

Exotic Mylar bags
Comics and collectibles

Archival clear bags.

Seasonal retail

Short digital runs for holiday designs such as Halloween Mylar bags.

How to Order Custom Mylar Bags

  1. 01Send format, size, fill weight and quantity. Your quote arrives within 24 hours.
  2. 02Select bottom style, finish, closure and add-ons.
  3. 03Upload artwork, or use free design support for dielines and layout.
  4. 04Approve the free digital proof. Production runs 2 to 3 business days.
  5. 05Receive your bags in 4 to 5 business days with free US shipping.

ARTWORK: AI OR PDF / CMYK / 300 DPI / 1/8 IN BLEED / TEXT 1/4 IN INSIDE SEALS / FONTS OUTLINED

Mylar Bag Spec Checklist: 8 Points to Confirm Before You Order

Supplier quotes differ because specs differ. Confirm these 8 points in writing before approving any quote:

  • Laminate structure named by layer, such as PET 12 µm / AL 7 µm / PE 80 µm
  • Total thickness in mil or microns
  • OTR and MVTR with the ASTM method
  • Closure type, and a CR test report if the product is regulated
  • Food-contact compliance letter
  • Print method and Pantone tolerance
  • Proof type: flat, 3D or physical sample
  • Overrun and underrun tolerance

Custom Mylar Bags FAQ

What is the minimum order for custom Mylar bags?

The minimum order is 500 units per design. Digital printing keeps short runs affordable, and the unit price drops at each higher quantity tier.

How long do custom Mylar bags take to arrive?

Custom Mylar bags arrive in 6 to 8 business days after proof approval: 2 to 3 business days of production and 4 to 5 business days of free shipping.

Can I print different designs in one order?

Yes. Digital printing runs several designs, flavors or strain names in one order without added setup cost.

Which add-ons can I put on a custom Mylar bag?

Every bag can take a resealable press-to-close zipper, a heat seal area above the zipper and a tear notch. Regulated products can use a child-resistant zipper lock tested to 16 CFR 1700.20 in place of the standard zipper.

What is the difference between Mylar and foil bags?

Mylar is the PET film layer, and foil is the aluminum barrier layer. Most Mylar bags combine both, which is why buyers use the 2 terms for the same pouch.

Are custom Mylar bags airtight?

Yes. A heat-sealed foil Mylar bag is airtight. A zipper alone slows air exchange, so seal above the zipper for long-term storage.

Do custom Mylar bags work with heat sealers?

Yes. The PE inner layer seals with impulse, band and direct heat sealers. Test the seal time on a blank bag before filling a full run.

Can I get a sample before production?

Yes. Every order includes a free digital proof with flat view and 3D mockup, and a physical sample is available on request before the full run.

Send your size, fill weight and artwork.

Your custom Mylar bags quote arrives within 24 hours. Bags ship in 6 to 8 business days after proof approval.

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