Packaging Guides
Custom Mylar Bags: The Complete Buyer's Guide for 2026
Cubit Packaging
April 8, 2026
Quick Answer: Custom mylar bags are branded, printed flexible packaging made from BoPET (biaxially-oriented polyethylene terephthalate) film that combines exceptional barrier properties with full-surface custom printing. The global flexible packaging market reached $228 billion in 2025 (Smithers), with custom mylar bags representing the fastest-growing segments. MOQs start at 100 units with digital printing, per-unit costs range from $0.15 to $2.50.
What Are Custom Mylar Bags?
A custom mylar bag is a flexible pouch made from polyester film (mylar/BoPET) that features your brand's custom artwork, logo, product information, and regulatory text printed directly onto the bag surface. Unlike generic plain bags, custom mylar bags serve as both packaging and marketing tools — every bag that reaches a customer is a branded touchpoint.
Custom printed mylar bags with full-color branding — available from Cubit Packaging
Why Brands Choose Custom Mylar Bags
| Benefit | Details |
|---|---|
| Barrier protection | Blocks 99.9% of moisture, oxygen, UV light, and odors |
| Custom branding | Full-color printing up to 10 colors with photo-quality artwork |
| Shelf life extension | Preserves freshness 3–10x longer than standard packaging |
| Lightweight | 70–80% lighter than rigid containers, reducing shipping costs |
| Versatile closures | Ziplock, tear notch, hang hole, valve, child-resistant options |
| Regulatory compliance | FDA food-safe, child-resistant ASTM D3475 certified options |
"72% of consumers say packaging design influences their purchasing decisions" — Ipsos Consumer Packaging Survey, 2025. Custom mylar bags convert shelf browsers into buyers.
Types of Custom Mylar Bags
By Style
| Type | Best For | Key Feature |
|---|---|---|
| Stand-Up Pouches | Retail shelves, farmers markets | Self-standing, maximum shelf visibility |
| Flat Mylar Bags | Samples, sachets, lightweight items | Compact, cost-effective |
| Kraft Mylar Bags | Organic brands, eco-conscious products | Natural aesthetic with mylar barrier |
| Clear Front Mylar Bags | Product showcase, visual appeal | Customers see the product before buying |
| Holographic Mylar Bags | Premium brands, limited editions | Eye-catching iridescent finish |
| Die-Cut Shaped Bags | Unique branding, novelty products | Custom shapes (circles, bottles, characters) |
Custom kraft mylar bags with natural eco-friendly appearance and full barrier protection
By Feature
| Feature | Product | Use Case |
|---|---|---|
| Smell-proof | Smell-Proof Mylar Bags | Cannabis, herbs, spices, pet treats |
| Child-resistant | Child-Resistant Mylar Bags | Cannabis, pharmaceuticals, edibles |
| Degassing valve | Mylar Bags with Valve | Coffee, freshly roasted products |
| Tear notch | Mylar Bags with Tear Notch | Single-serve snacks, samples |
| Hang hole | Mylar Bags with Hang Hole | Retail peg displays |
| Matte finish | Matte Mylar Bags | Premium, luxury aesthetic |
Material & Thickness Guide
A typical custom mylar bag has a multi-layer laminated structure: PET outer layer (print surface + strength), aluminum foil middle layer (barrier against O₂, moisture, light), and PE inner layer (food-safe contact + heat-seal capability).
| Thickness | Weight Feel | Best For | Shelf Life |
|---|---|---|---|
| 3 mil | Thin, flexible | Samples, lightweight snacks | 6–12 months |
| 3.5 mil | Standard retail | Most food products, retail | 1–2 years |
| 4 mil | Sturdy | Coffee, tea, premium products | 2–5 years |
| 5 mil | Heavy-duty | Long-term food, supplements | 5–25 years |
| 7 mil | Very rigid | Emergency food, industrial | 25+ years |
Expert recommendation: For most custom branded retail products, 3.5–4 mil provides the ideal balance of product protection, packaging feel, and cost. For food storage, always choose 5 mil or higher.
Printing Methods
Digital Printing
- Best for: Short runs (100–5,000 units), prototype testing, multiple SKUs
- Colors: Full CMYK, unlimited colors
- MOQ: As low as 100 bags
- Lead time: 5–10 business days
- Cost per unit: $0.50–$2.50
Rotogravure Printing
- Best for: Large runs (10,000+ units), highest print quality
- Colors: Up to 10 spot colors with Pantone matching
- MOQ: 10,000–25,000 bags
- Lead time: 15–25 business days
- Cost per unit: $0.15–$0.75
Child-resistant mylar bags with custom printing — ASTM D3475 certified for cannabis and pharmaceutical packaging
Pricing Guide
| Order Size | Price Per Unit | Total Investment |
|---|---|---|
| 100–500 bags | $1.50–$2.50 | $150–$1,250 |
| 500–2,000 bags | $0.75–$1.50 | $375–$3,000 |
| 2,000–5,000 bags | $0.40–$0.90 | $800–$4,500 |
| 5,000–10,000 bags | $0.25–$0.60 | $1,250–$6,000 |
| 10,000+ bags | $0.15–$0.40 | $1,500+ |
How to Choose a Supplier
7 Questions to Ask Every Supplier
- What is your minimum order quantity? — Lower MOQs = less risk for new brands
- Do you offer design assistance? — Good suppliers provide free design support
- What certifications do you have? — Look for FDA, ISO 9001, ASTM D3475
- Can I order a sample first? — Never commit without sampling
- What is the lead time? — Digital: 5–10 days, Gravure: 15–25 days
- Do you offer child-resistant options? — Essential for compliance
- What happens with quality issues? — Look for reprint/refund guarantees
Why Cubit Packaging?
| Feature | Cubit Packaging | Typical Suppliers |
|---|---|---|
| MOQ | 100 bags | 5,000–25,000 bags |
| Design support | Free AI Design Studio | Extra charge or none |
| Lead time | 5–15 business days | 20–35 business days |
| Sampling | Available before bulk | Often not available |
| Pricing | Transparent instant quotes | Weeks of back-and-forth |
Flat mylar bags — cost-effective custom packaging for samples, sachets, and single-serve products
Frequently Asked Questions
What is the minimum order for custom mylar bags?
At Cubit Packaging, the minimum order for custom printed mylar bags is 100 units with digital printing. Rotogravure printing requires 10,000+ units. Digital printing allows startups and small brands to order custom branded packaging without large upfront investment.
How long does it take to get custom mylar bags?
Production time ranges from 5 to 25 business days. Digital printing (100–5,000 bags) ships in 5–10 days. Gravure printing (10,000+ bags) takes 15–25 days due to cylinder engraving. Rush options are available.
Are custom mylar bags food safe?
Yes, food-grade custom mylar bags use FDA 21 CFR compliant inner linings (polyethylene or cast polypropylene). All Cubit Packaging mylar bags for food use meet FDA food contact requirements and are manufactured in ISO 9001 certified facilities.
Can I get custom mylar bags with child-resistant features?
Yes, child-resistant mylar bags comply with ASTM D3475 — required by law in many states for cannabis, edible, and pharmaceutical products. Features include press-to-close zippers requiring simultaneous pinching and sliding.
What file format do I need for custom artwork?
Submit artwork as a vector file (AI, EPS, or PDF) at minimum 300 DPI. No design files? Use our free AI Design Studio to create print-ready artwork without professional software.
Custom mylar bags vs stock bags: Which is better?
Custom bags are better for retail and DTC brands — they build brand recognition, communicate product info, and meet labeling requirements on the packaging itself. Custom printing adds only $0.10–$0.30 per unit while significantly increasing perceived product value.
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