A Must-Read Guide on How to Make Custom Mylar Bags 

With ever-increasing globalization, we can observe an increase in the demand for packaging. Besides this, customers also need packaging that can retain product quality and freshness for a long duration. One type of packaging that is lightweight and highly protective is a custom Mylar bag. This bag has significant protective ability against the following: 

• Oxygen
• Moisture
• Light
• Odors
• Handling damage

From protection to presentation, these pouches come with several benefits. Nonetheless, the overall functionality of the bags depends on their style and manufacturing raw material. In this blog, Custom Boxes Market has explained the manufacturing of custom Mylar packaging. 

What Are Custom Mylar Bags?

Mylars are flexible pouches that are manufactured with multilayer films. Their commercial name is BoPET (biaxially oriented polyethylene terephthalate), which signifies a high-barrier film with resistance properties. The common layers used in the manufacturing of Mylar are as follows: 

• Polyester
• Aluminum foil or metallized film
• Polyethylene 
• Heat-sealable layer

Oxygen and moisture protection is provided by the compact structure of multiple layers. The inner seal of customized Mylar bags allows a perfect seal to the pouches. Customization allows the following features: 

• Stand-up construction
• Flat pouch construction
• Side gussets
• Bottom gussets
• Zipper closures
• Tear notches
• Hang holes
• Heat seals
• Child-resistant features where appropriate
• Transparent windows
• Custom printed graphics

How Do You Make Mylar Bags?

The manufacture of Mylar pouches depends largely on the type of material you are going to pack. Brands have to do periodic assessments for:

• Material selection
• Bag design
• Artwork preparation
• Printing
• Lamination
• Pouch conversion
• Sealing
• Quality inspection.

The detailed process of bag manufacturing is as follows: 

Identify the Product Requirements

Your first step is to identify the needs of your product. Start asking about the factors against which products need protection. Different products have different packaging requirements. A dry snack will need moisture and oxygen resistance. On the other hand, light-sensitive products require UV resistance. Some of the products are sensitive to aromas and need smell-proof Mylar bags and so on. So, before making any final decisions, consider the following and do not choose bags only based on appearance: 

• Product type
• Product weight
• Product volume
• Moisture sensitivity
• Oxygen sensitivity
• Light sensitivity
• Aroma sensitivity
• Shelf-life target
• Filling method
• Storage conditions
• Distribution environment
• Closure requirements

Choose the Mylar Bag Material Structure

The next step in the manufacture of Mylar bag designs is the selection of materials. Commercial pouches are manufactured with multiple layers, and each gives a unique property. You have to first identify the properties provided by the material: 

PET Layer

• Strength
• Printability
• Surface durability
• Dimensional stability

Aluminum Foil Layer

• Light
• Oxygen
• Moisture
• Aroma transmission

Metallized Film

The purpose of metallized films is to give metal properties and can be used when the high-end barrier quality of aluminium is not required. Metallized films are commonly used in the manufacturing of holographic mylar bags. 

PE Layer

• Inner heat sealing
• Flexibility
• Product-contact functionality when the selected grade is suitable
• Puncture resistance

Determine the Bag Size

The correct dimensions of your pouches are essential. If your pouch contains a gusset, then consider the width and height of the pouch’s gusset measurement. On the other hand, flat pouches can be measured with only width and height. In stand-up pouches, it is vital that you use the measurement of the bottom gusset and so on. Make sure that you are not selecting the dimensions of a pouch only on the base of the pouch’s physical structure. The bags also need areas for sealing and filling. For instance, powder and dense snacks require different dimensions due to the difference in bulk densities. So always test the packaging when ordering or making in bulk quantities. Brands must also consider several other factors at the time of measuring the dimensions, such as: 

• Product fill weight
• Product density
• Fill level
• Headspace
• Closure position
• Seal area
• Product shape
• Filling equipment

Select the Bag Style

The next step is to select the style of the pouches. This also depends on the type of food and the serving sizes. You can see the table below for custom Mylar bag wholesale styles: 

Create the Custom Artwork

After selecting the style and the rest of the specifications of your bags, you can now select the artwork for the pouches. The exact artwork information depends on the branding needs and food labelling requirements. Make sure that the important components of the packaging are away from the seal or opening of the pouches, as the sealing needs proper space for a perfect pouch shape, and you may end up masking the important information. Your packaging provider will produce a die line that may have: 

• Cut lines
• Fold lines
• Seal areas
• Gussets
• Zipper location
• Safe artwork zones

You can select any design for the packaging to get custom artwork on Mylar bags. Some of them are as follows: 

• Brand name
• Logo
• Product name
• Product information
• Ingredients
• Net quantity
• Directions
• Storage information
• Barcode
• Regulatory information
• Contact information
• Required warnings

 Select the Printing Method

For custom printed mylar bags, there are several types of printing methods available in the market. These printing methods are selected based on the quantity of t bags and the complexity of the artwork. The common processes are as follows: 

• Digital Printing
• Rotogravure Printing
• Flexographic Printing

Your manufacturer will provide different types of printing based on the type of design and the color. For photographic designs, CMYK is the best option. PMS works well for logos. The best printing processes depend on: 

• Quantity
• Artwork
• Number of colors
• Required consistency
• Production budget
• Lead time

Laminate the Film Layers

Yale bags have multiple layers that need to be laminated to create a single sheet. This combination is important to create a single functional packaging structure where each layer performs its intended role. For instance:

Outer layer → Print and strength

Barrier layer → Oxygen, moisture, and light protection

Inner layer → Heat sealing and product-contact function

For high-quality pouches, it is pertinent that the adhesives and lamination process are compatible with the selected films and intended application. The commercial manufacturing of mylars requires controlled manufacturing to avoid any errors.  A low-quality lamination can cause multiple problems like: 

• Delamination
• Wrinkling
• Weak bonds
• Poor appearance
• Seal failures

Convert the Film Into Bags

After printing and laminating the raw material, the film is converted into pouches. There are several steps in bag formation, and the exact sequence of the steps varies from one style to the other. Even small dimensional errors can have large effects, such as errors in filling and sealing. Depending on the style of pouch a brand prefers, the manufacturing process can involve: 

• Slitting the material
• Folding the film
• Adding a zipper when required
• Creating gussets
• Forming the pouch
• Cutting the individual bags
• Creating tear notches or hang holes
• Heat sealing the required edges

Conclusion!

The manufacturing process of mylar bags needs sophisticated machinery and synchronized processes. Missing any steps or any error in the process can result in packaging with no useful qualities. Each step is interconnected with the next one and affects the final protective ability of the custom mylar bags. For high-quality and affordable mylar packaging, you can contact Custom Boxes, Market. A packaging company that manufactures wholesale pouches at a low MOQ. So contact me now and get highly professional Mylar bag manufacturing services in the USA!