Custom Sealed Mylar Bags

A sealed pouch built around the actual fill

Custom sealed mylar bags give a brand a flexible printed format that can be sized around the product instead of forcing a measured fill into a generic stock envelope. Begin with the packed length, width, height, widest points, fill weight, and any inner wrap or scoop. Those details determine the panel proportions, headspace, gusset depth, seal margin, and whether a flat or stand-up structure is practical. A pouch that is too tight can push product into the crimp; one with excessive empty space can fold across the artwork and make the pack difficult to stack.

The film structure should follow the product rather than the product being asked to fit an assumed material. Food-grade flexible pouch film can be combined with a metalized or foil barrier laminate and a polyethylene sealant layer where the product needs a considered response to moisture, aroma, oxygen, or light. The barrier is not a universal shelf-life guarantee. Recipe, water activity, filling temperature, headspace, storage route, and time in market all matter, so those variables belong in the quote brief. For dry coffee, tea, spices, bakery mixes, nuts, supplements, or pet treats, the recommended structure may differ even when the outside shape looks similar.

A heat seal closes the package after filling and can be paired with a tear notch for a controlled first opening. If customers need to reopen the bag, a zipper can be positioned below the seal, provided the packed product leaves enough clearance for the track and top crimp. The closure choice should match the filling line and the way the product is stored after opening. Mark the seal-safe zone in the artwork so the front brand cue and the back handling information remain readable once the top edge is trimmed or folded.

Use the front panel to identify the product quickly and the back panel for ingredients, preparation or storage notes, barcode placement, lot space, and required copy. Matte lamination can reduce glare around product photography and illustrated ingredients. Gloss lamination can increase color contrast on a bold mark, while spot gloss or spot UV can highlight a small logo without changing the whole surface. Metallic ink or a foil accent may be appropriate for selected linework, subject to film and artwork review. Keep critical copy away from folds, gussets, zipper tracks, and the crimp because those areas move when the pouch is filled.

The pictured print is an example of artwork placement, and your approved brand artwork takes its place once the proof is signed off. On the digital proof, check the front and back orientation, seal margin, tear-notch position, gusset folds, window placement if requested, and the way the filled bag stands or lies. Proof review is the right point to correct copy, panel boundaries, and closure placement before production.

Minimum order, timing, and proof

The standard fulfillment path starts at 50 units, with production from 7 business days after digital proof approval. Free US shipping is an approved service fact for the standard path, and dieline and proof review are included at no extra charge. Quote requests are typically answered the same business day and always within 24 hours. Pricing stays quote-only for this page because film structure, dimensions, closure, print coverage, finish, and quantity change the actual cost.

For a useful review, send a filled sample or measured dummy, the packed weight, target count per case, storage conditions, sealing equipment, and artwork status. Note whether the bag needs a window, tear notch, zipper, degassing feature, or simple top seal. A sample kit has a $44.99 USD shipping charge credited toward the first order, giving a practical way to compare film feel, opacity, seal behavior, and finish before approving a custom run.

Make the proof easy to check

A clear brief prevents common sealed-pouch surprises: product caught in the crimp, a brand mark hidden by a gusset, or a closure placed where the filled bag cannot close flat. Mark the intended front panel, opening edge, reading direction, no-print zones, and barcode area. If the product is packed in multiple units, show the complete arrangement rather than one item. The resulting proof can then be reviewed for fit, print legibility, barrier direction, and the handling routine together.