Mylar Bags

Custom Printed Mylar Bags UK

Protect and present food, coffee, supplements, confectionery, cosmetics and other suitable products in flexible packaging made around your requirements.

All Custom Packaging produces custom Mylar bags for independent businesses, online retailers, food producers, wellness brands and established companies across the UK. Every pouch can be tailored according to the product, target fill weight, required barrier, shelf presentation and customer opening experience.

Orders start from 100 units per design, allowing smaller brands to test a new product, flavour or printed pouch without committing to several thousand units. There are no setup fees, and free design support and a free 3D mockup are included.

Once the design and sample have been approved, production normally takes 6 to 8 business days. You can review a video of the physical sample before the full run is produced, and every completed order includes free UK delivery.

What Is a Mylar Bag?

“Mylar” is widely used in the packaging trade to describe pouches that include a strong polyester film layer. Technically, Mylar® is a recognised brand of biaxially oriented polyethylene terephthalate, also known as BOPET or PET film.

Most retail Mylar-style pouches are not made from one material alone. They use a laminated structure that can combine:

• A printable PET or BOPET outer layer
• Metallised PET or aluminium foil for additional barrier
• Polyethylene or another suitable inner sealing layer
• Adhesives that bond the film layers
• Optional paper, clear or speciality decorative surfaces

The exact construction is selected according to the product. A transparent sweet pouch, a foil coffee bag and a frozen-food pouch do not require the same film structure.

Metallised and foil laminate options can provide increased resistance to oxygen, moisture, light and aroma. However, the performance depends on the full laminate, film thickness, seals, zipper and any window or valve included in the design.

Why Brands Order Mylar Bags from All Custom Packaging

A custom pouch combines product protection, printed information and brand presentation in one lightweight format.

Standard bags are normally limited to fixed dimensions, colours and features. A bespoke pouch can be developed around:

• The product type
• Target fill weight
• Product density
• Required headspace
• Moisture and oxygen sensitivity
• Aroma-control requirements
• Retail or e-commerce use
• Resealable or permanent closures
• Window and valve requirements
• Printing and finish
• Required product information

This gives the product a more deliberate fit and allows branding, ingredients, directions, barcodes and other information to be printed directly onto the pouch.

Our service includes:

• Minimum quantities from 100 units per design
• No setup fees
• Bespoke sizes and fill capacities
• Free packaging design support
• A free 3D mockup
• Full-colour printed branding
• Zipper, tear-notch and window options
• Physical sample video approval
• Production in 6 to 8 business days after approval
• Free delivery throughout the UK

Mylar Bag Styles and Features

Stand-up pouches use a gusseted base that opens as the bag is filled. This allows the finished pack to stand upright on a retail shelf.

They are suitable for:

• Coffee and tea
• Confectionery
• Dried fruit and nuts
• Snacks
• Protein powders
• Supplements
• Pet treats
• Spices
• Bath salts
• Refill products

A broad front and back panel provides space for branding, product information and instructions.

Explore Small Mylar Bags for compact products, samples and lower fill weights.

Flat Mylar Bags

Flat pouches do not use a stand-up base and are suitable for smaller, lighter or single-use products.

They can be used for:

• Samples
• Individual portions
• Sachet-style products
• Small accessories
• Flat items
• Single-use treatments
• Lightweight confectionery
• Promotional packs

Flat bags occupy less space before filling and can be heat-sealed across the top.

Zipper Mylar Bags

Our Zipper Mylar Bags include a press-to-close resealable closure.

A zipper allows the customer to open the pouch, remove part of the contents and close it again. It is useful for products that are not normally consumed in one use, including:

• Coffee
• Tea
• Snacks
• Sweets
• Supplements
• Protein powder
• Pet treats
• Herbs and spices

A zipper is a convenience feature, but it is not automatically tamper-evident. Where evidence of first opening is required, a heat-sealed section can be added above the zipper and removed using tear notches.

High-Aroma-Barrier and Smell-Resistant Bags

Our Smell Proof Mylar Bags can be specified with higher-barrier laminate structures intended to reduce the transfer of strong aromas.

These bags may be suitable for:

• Coffee
• Tea
• Spices
• Botanicals
• Pet treats
• Fragranced bath products
• Strongly scented products

The term “smell proof” should not be treated as an unlimited guarantee. Aroma performance depends on the film structure, zipper, heat seals, storage conditions and product formulation.

Where aroma retention is critical, the final pouch should be tested with the actual product.

Child-Resistant Mylar Bags

Our Child Resistant Mylar Bags can be considered for lawful products that require an additional access-control feature.

Possible closures include press-and-slide or other specialist zipper mechanisms. A standard resealable zipper is not automatically child-resistant.

To make a child-resistant claim, the complete package and closure should be tested and certified against the relevant standard. BS EN ISO 8317 applies to testing reclosable child-resistant packaging. Product owners must also confirm the legal packaging requirements that apply to the contents.

Child-resistant packaging is not childproof and does not replace appropriate warnings, responsible storage or legal compliance.

Window Mylar Bags

A transparent window allows customers to see the product before purchasing.

Windows can be useful for:

• Sweets and confectionery
• Dried fruit
• Nuts
• Tea
• Pet treats
• Bakery products
• Craft and small retail items

Explore Transparent Mylar Bags for clear or partly transparent formats.

A window may reduce the pouch’s protection against light and can alter oxygen or moisture-barrier performance. Its size and position should therefore be planned around both presentation and product sensitivity.

Kraft-Look Mylar Bags

Our Kraft Mylar Bags combine a natural paper appearance with a flexible inner pouch structure.

They work well for:

• Artisan foods
• Herbal tea
• Coffee
• Handmade products
• Bath salts
• Natural snacks
• Organic-style branding

A kraft appearance does not necessarily mean the complete pouch is made from paper or can enter household paper recycling. Many kraft-look pouches contain plastic and metallised laminate layers.

Environmental and disposal claims should be based on the complete material specification rather than the appearance of the outer surface.

Holographic Mylar Bags

Our Holographic Mylar Bags use a reflective surface that changes appearance under different lighting and viewing angles.

They are suitable for:

• Confectionery
• Cosmetics
• Accessories
• Promotional products
• Limited-edition collections
• Event products
• Youth-focused brands

The holographic surface can be combined with printed logos, clear areas and resealable closures.

Black Mylar Bags

Our Black Mylar Bags provide a strong, simple base for white, metallic or bright printed artwork.

Black pouches are commonly used for:

• Coffee
• Supplements
• Luxury confectionery
• Cosmetics
• Men’s grooming products
• Premium pet treats
• Limited-edition ranges

The front and back panels can include full product branding or remain minimal with a single logo and product label.

Blank Mylar Bags

Our Blank Mylar Bags provide an unprinted option for businesses that prefer to add branding and product details separately.

Plain bags can be finished with:

• Printed labels
• Branded stickers
• Batch panels
• Thermal labels
• Hand-applied flavour labels
• Date coding
• Barcodes
• Rubber stamps

Blank pouches are useful for frequently changing products, test launches, small market runs and businesses using one bag across several flavours.

Gusseted Mylar Bags

Gusseted pouches expand at the base or sides to provide additional internal volume.

They are suitable for:

• Larger fill weights
• Bulky snacks
• Pet food
• Coffee
• Powders
• Dried foods
• Refill products

The gusset dimensions should be based on the filled product rather than the empty pouch alone.

Valve Coffee Bags

Coffee pouches can include a one-way degassing valve where required by the product and packing process.

The valve allows gases released by roasted coffee to leave the pouch while helping limit outside air entering through the same opening.

Valve placement should consider:

• Coffee type
• Roast date
• Fill weight
• Pouch dimensions
• Heat-seal area
• Retail presentation

A valve is normally unnecessary for products that do not release gas after packing.

Die-Cut and Shaped Pouches

Custom die-cut pouches can use a distinctive outline rather than a conventional rectangle.

They can be created for:

• Promotional campaigns
• Confectionery
• Samples
• Cosmetics
• Event products
• Children’s products
• Seasonal collections

The shape must leave enough space for secure seals, product information and practical filling.

Specialist Anti-Static Pouches

Anti-static and static-shielding pouches are specialist formats for electronic components and sensitive equipment.

They require verified material structures developed specifically for electrostatic protection. An ordinary metallised retail pouch should not automatically be described as anti-static or suitable for electronic components.

Mylar Bag Sizes and Fill Weights

Mylar pouches can be made around the intended fill rather than restricted to fixed stock dimensions.

Common target fills include:

• 3.5g
• 7g
• 28g
• 50g
• 100g
• 250g
• 500g
• 1kg
• Larger bespoke quantities

Fill weight alone does not determine the correct pouch size. Different products have different densities.

For example, 100g of coffee beans, 100g of protein powder and 100g of sweets can occupy very different volumes.

To calculate a suitable pouch size, provide:

• Product type
• Target fill weight
• Approximate product density
• Largest product pieces
• Required headspace
• Zipper or heat-seal area
• Whether the pouch must stand
• Window or valve requirements
• Filling method

Enough headspace should remain for clean filling and reliable sealing without making the pouch look unnecessarily empty.

Materials Used in Mylar-Style Pouches

PET or BOPET Film

PET is often used as an outer layer because it provides strength, dimensional stability and a suitable surface for printing.

It may form part of a clear, printed, metallised or laminated pouch structure.

Metallised PET

Metallised PET uses a very thin metallic coating applied to polyester film. It can improve light, oxygen, moisture and aroma-barrier performance without the full thickness of aluminium foil.

The actual result depends on the complete laminate and coating quality.

Aluminium Foil

Aluminium foil can be included as a high-barrier layer where stronger protection from light, oxygen, moisture or aroma is required.

Foil laminates are commonly considered for:

• Coffee
• Powdered supplements
• Sensitive dry foods
• Strongly fragranced products
• Products intended for longer storage

Foil can increase the material complexity of the pouch and affect its recycling route.

Polyethylene Sealing Layer

Polyethylene is commonly used as an inner sealant layer because it can form a reliable heat seal.

Where the pouch is intended for food, the complete food-contact layer and laminate must be suitable for the product and conditions of use.

BOPP Film

BOPP may be used in selected flexible packaging structures for strength, clarity, moisture resistance and print performance.

It can be suitable for dry snacks, confectionery, bakery products and other products where the complete laminate meets the required performance.

Kraft Paper Layer

Kraft paper may be used as part of the outer appearance of a laminate.

It gives the pouch a natural texture but does not alone provide the moisture, oxygen or aroma barrier associated with a metallised structure.

Clear Film

Clear laminates provide maximum product visibility but normally offer less protection from light than opaque or metallised pouches.

The correct choice depends on whether product visibility or light protection is more important.

Choosing the Correct Barrier

The highest-barrier film is not automatically necessary for every product.

The appropriate structure depends on:

• Product sensitivity
• Required shelf life
• Oils and fats
• Moisture content
• Aroma
• Exposure to light
• Storage temperature
• Distribution journey
• Resealing requirements
• Filling and sealing equipment

A dry, fast-selling confectionery product may not require the same laminate as freshly roasted coffee or a sensitive powdered supplement.

Packaging can support shelf life, but it does not independently establish it. Brands should test the final pouch with the actual product under realistic storage and distribution conditions.

Closure and Opening Options

Press-to-Close Zipper

A standard resealable closure for snacks, coffee, powders and products used over several occasions.

Child-Resistant Zipper

A specialist closure that requires a particular opening action. Any child-resistant claim must be supported by testing of the finished package.

Slider Zipper

A sliding closure that can provide easier opening and reclosing for selected larger pouch formats.

Tear Notches

Small notches guide the customer when tearing open the sealed top section.

Heat Seal

A permanent top seal made using suitable heat-sealing equipment. It can be used above a zipper to provide evidence of first opening.

Tamper-Evident Top Section

A sealed strip above the zipper that must be torn or cut before the resealable closure can be reached.

Easy-Peel Seal

A seal developed to open with controlled force where suitable materials and filling systems are used.

One-Way Valve

A specialist feature used mainly for freshly roasted coffee and other products that release gas after filling.

Printing Custom Mylar Bags

Your pouch can be printed with full product artwork rather than relying on separate front and back labels.

Artwork can include:

• Brand logos
• Product names
• Flavour or fragrance variants
• Ingredients
• Allergen information
• Nutrition information
• Directions for use
• Serving information
• Batch and date areas
• Barcodes
• QR codes
• Website and contact details
• Storage instructions
• Disposal guidance
• Warning information

Printing may use digital production for shorter runs or flexographic and gravure processes for suitable larger-volume orders. The recommended method depends on the quantity, film structure, artwork and required colour consistency.

Colour and Finish Options

Full CMYK Printing

Suitable for detailed artwork, illustrations, gradients, product images and designs using several colours.

Pantone Colour Matching

Pantone references can be used where closer consistency with established brand colours is required.

The final appearance can vary according to whether the film is white, clear, kraft-look, metallic or holographic.

Matt Finish

Creates a low-reflection surface for modern, understated and premium packaging.

Gloss Finish

Provides a shinier surface and can make printed colours appear brighter.

Soft-Touch Finish

Adds a smooth tactile surface to suitable premium pouch structures.

Metallic and Holographic Effects

Allow the reflective film surface to form part of the design.

Clear Areas

Selected parts of the artwork can remain transparent to show the contents.

Mylar Bags for Different Industries

Custom pouches can be developed for:

• Coffee and tea
• Confectionery
• Dried fruit and nuts
• Spices and seasoning
• Protein and fitness nutrition
• Food supplements
• Pet food and treats
• Cosmetics and skincare
• Bath salts and personal care
• Herbal products
• Frozen products using a suitable cold-resistant laminate
• Household and refill products
• Lawful CBD and regulated products where the packaging specification and labelling meet the relevant requirements

The material, closure and printed information must be selected for the actual product. One pouch specification should not automatically be used across unrelated industries.

Food-Contact and UK Labelling Considerations

When a pouch is used for food, the complete structure must be suitable for the product and the conditions in which it will be filled, stored and sold.

This includes consideration of:

• Inner food-contact film
• Printing inks
• Adhesives
• Product temperature
• Oils and fats
• Moisture
• Contact duration
• Storage conditions
• Sealing process

UK guidance requires businesses packaging food to use materials suitable for food use and to retain evidence of compliance where required.

The printed artwork may also need space for:

• Name of the food
• Ingredients
• Emphasised allergens
• Net quantity
• Date information
• Storage instructions
• Business details
• Nutrition information
• Required warnings
• Batch coding

The exact requirements depend on the product and how it is sold. All Custom Packaging can arrange supplied information, but the food business remains responsible for checking and approving the final wording.

Recycling and Disposal Claims

Many Mylar-style bags use several bonded materials, which can make them unsuitable for ordinary household paper or single-material plastic recycling.

The correct disposal route depends on:

• Film layers
• Metallisation or foil
• Kraft-paper layers
• Zippers
• Valves
• Windows
• Adhesives
• Local collection facilities

A kraft appearance does not mean the pouch belongs in paper recycling, and a metallised pouch should not automatically be described as recyclable.

Disposal instructions should be confirmed against the final laminate and the collection routes available to the intended customer.

Coordinate Your Flexible Packaging Range

Mylar bags can be matched with:

• Custom product boxes
• Mailer boxes
• Printed labels
• Branded stickers
• Display boxes
• Tissue paper
• Retail cartons
• Shipping boxes

Using the same Pantone references, typography and design elements across pouches and boxes helps create a consistent product range.

How Ordering Works

1. Send Your Product Details

Provide the product type, target fill weight, quantity and preferred pouch style.

Include information about:

• Product density
• Required barrier
• Zipper or permanent seal
• Window or valve
• Retail or e-commerce use
• Food-contact requirements
• Printed information

2. Select the Material and Features

Our team will help you choose a suitable pouch structure, dimensions, closure and finish.

3. Review the Free 3D Mockup

Our designers prepare the artwork and send a free 3D mockup showing the proposed pouch and print placement.

4. Approve the Physical Sample

You receive a video of the physical sample showing:

• Pouch size
• Gusset and shape
• Zipper
• Tear notches
• Window or valve
• Printed colours
• Surface finish
• Overall presentation

5. Production and UK Delivery

Production normally takes 6 to 8 business days after final approval. The completed order is delivered free of charge throughout the UK.

Order Custom Printed Mylar Bags

To request an accurate quotation, provide:

• Product type
• Target fill weight
• Approximate product density
• Required quantity
• Preferred pouch style
• Required barrier performance
• Zipper, valve or window requirements
• Food-contact or specialist requirements
• Artwork and Pantone references
• Required product-information panels
• Matt, gloss, metallic or other finish

Our team will review the details and recommend a suitable pouch size, material structure and closure.

Frequently Asked Questions

What are custom Mylar bags?

Custom Mylar bags are printed flexible pouches that commonly include a PET-based film within a multilayer laminate. They can be customised in size, artwork, closure and barrier structure.

Are all Mylar bags made from aluminium foil?

No. Some use metallised PET, some include aluminium foil, and others use clear or white plastic-film laminates. The correct structure depends on the product.

What is the minimum order quantity?

Orders start from 100 units per design. The most suitable production method and unit price depend on the pouch dimensions, material, artwork and quantity.

Can you make bags for a specific fill weight?

Yes. Pouches can be developed for fills such as 3.5g, 7g, 28g, 100g, 250g, 500g and 1kg. Product density is also required because equal weights can occupy different volumes.

Are resealable zippers available?

Yes. Press-to-close, slider and specialist closure options may be available depending on the pouch format.

Is a zipper tamper-evident?

Not by itself. A heat-sealed top section can be added above the zipper so the customer must remove it before first use.

Are child-resistant Mylar bags available?

Specialist child-resistant closures can be considered. Any child-resistant claim should be supported by appropriate testing of the complete finished package.

Can a window be added?

Yes. Clear windows can be added to suitable pouches, although they may reduce protection from light and affect the overall barrier.

Are smell-proof bags available?

Higher-aroma-barrier structures can be produced, but performance depends on the complete laminate and seals. The finished pouch should be tested with the actual product.

Can coffee bags include a valve?

Yes. One-way degassing valves can be added where required for freshly roasted coffee.

Can Mylar bags be used for food?

Yes, where the complete pouch, inner film, adhesives and inks are suitable for the intended food and conditions of use.

Can the bags be printed in full colour?

Yes. Full CMYK artwork, Pantone matching, matt, gloss, metallic and speciality design options are available according to the selected film.

Are kraft Mylar bags recyclable with paper?

Usually not automatically. Kraft-look pouches often include bonded plastic or metallised layers and should be assessed according to the complete construction.

Can I order blank bags?

Yes. Blank Mylar bags can be supplied for businesses that apply their own labels, batch information or branding.

Can I approve the design before production?

Yes. You receive a free 3D mockup and can approve a video of the physical sample before the complete run begins.

How long does production take?

Production normally takes 6 to 8 business days after the final design and sample have been approved.

Is delivery available throughout the UK?

Yes. Completed custom Mylar-bag orders include free delivery throughout the United Kingdom.