Items with branded packaging are 30% more likely to be shared socially.

81% of consumers have purchased a new product since the packaging attracted them.

63% of entrepreneurs recommend personalized packaging builds brand recognition.

68% of shoppers believe good quality packaging means good quality products.

52% of customers shopping online will reorder from a premium packaging brand.

38% of the businesses that switched to printed-to-order packaging experienced an increase in sales in six months.

70% of shoppers report that they make their first impression of a brand when considering its package.

72% of consumers recommend packaging design is an aspect that influences their purchasing decisions.

Let’s start simple. You’ve probably seen sleek, shiny bags on store shelves holding coffee, snacks, or edibles and wondered, what makes them so popular? Those are Mylar bags, and they’ve quietly become the gold standard for packaging that protects, seals, and shows off your brand at the same time.

But purchasing custom printed Mylar bags is just as much about appearance. It's all about trust. A customer taking your bag home needs to trust that what's within is fresh, safe, and made by someone who truly cares. That's what good packaging communicates, it represents you.

What Exactly Is a Mylar Bag?

"Mylar" originated as a brand name for a type of polyester film, but it's come to be used for tough, laminated bags in general. Each consists of several layers with distinct functions:

1. The outer layer provides hardness and good prints.
2. The middle layer provides the barrier that excludes oxygen, light, and water.
3. The inside layer seals the package and keeps your product from being contaminated.

Together, those layers form a barrier stronger than paper or plastic alone. The result? Longer shelf life, brighter graphics, and a professional look that feels like your brand means business.

Finding the Right Size, Thickness, and Style

Choosing the right bag isn’t as simple as clicking “Add to Cart.” You’ll need to think about size, structure, and features that fit your product and your audience.

Size & Format

Consider where your product will lie in the bag. You don't want to take up unnecessary space or pay for it unnecessarily. Standard types are:

• Flat bags for long, thin items such as powders or single-serve foods.
• Stand-up bags which stand up on shelves for maximum visibility.
• Gusset bags for heavy or bulk items.
• Windowed types so customers can see what's inside.
• Child-resistant types if you're selling marijuana or other product that needs it.

Thickness & Barrier Strength

In mils or microns. The more heavily weighted bags will be more protective but more expensive. Rough guide:

• 2.5–3 mil for light weight articles.
• 4 mil for most merchandise retail items.
• 5 mil for heavy duty storage or long shelf life.

But thickness is just half the battle. The real unsung heroes are the barrier layers, keeping oxygen and moisture out. When packing something fragile such as coffee, jerky, or herbs, stick closely to those specs.

Other Features Worth Adding

Some add-ons make a big difference:

• Reseal zippers when opening.
• Tear notches so customers won't need scissors.
• Hang holes for display on store rack.
• Round corners for safety and comfort.
• Coffee degassing or air release valves.

These tiny details cost more up front but can prevent customer complaints down the road.

Printing: How it Works and What to Watch Out For

Printing is where material meets your creative vision. And that's where most starters make their first major blunder — picking the wrong technique or neglecting to proof.

Primary Printing Methods

There are several widely used methods, each with advantages and disadvantages:

1. Digital printing - Well suited for small print runs, rapid turnaround, and continuous design changes. No setup plates.

2. Flexographic printing - Excellent price-quality combination, best suited for mid-size runs.

3. Rotogravure - High quality, even, and rich, but with large minimum orders.

4. Screen printing - Well suited for bold graphics with 1 colors, not as well suited for gradients or detailed art.

Your decision relies on how many bags you order, your complexity of design, and how frequently you reorder.

Color, Finish & Readability

Folks are influenced by color prior to words even having a chance. A matte bag is peaceful, heavy, and high-end,  the sort of finish that speaks quietly of greatness. Gloss screams. It shines in the light, bragging like a spotlight upon the stage. There is no correct answer here, only the sense you desire your customer to leave with.

Watch out for small fonts and skinny lines, especially if you’re printing over metallic material. They can fade, smear, or vanish entirely. Always, always ask for a real printed sample before locking in your final order. Screens lie. Paper and film don’t.

Minimum Orders & Setup

Printing isn't ink; it's setup. There's a front-end cost to each process. New brands testing the waters with a short run or an occasional short run? Use digital printers. Flexo and gravure? Big runs. They require plates, so there's more up-front expense.

If you’re new, go small first. Run a few hundred, see how customers respond, and then scale up. It’s better to adjust early than be stuck with thousands of bags that don’t feel right.

How to Choose the Right Supplier

A good supplier is practically a business partner, not a vendor. They don't simply print; they advise you. They answer questions, caution you against errors, and even pick up the phone when you call.

What it comes down to:

• Transparent pricing without surprises.
• Clear communication and genuine timelines.
• Samples.
• Consistent print quality batch after batch.
• Respect for your timeline.

If they rush, ignore details, or brush off proof requests, get out. It's an indication of impending trouble.

The Buying Process in Simple Steps

Learn about your product. Your size, thickness, weight, and shelf life all determine your packaging selection.

1. Choose your design. Flat, stand-up, gusseted, consider how it will rest on the shelf.

2. Get quotations. Shop for custom mylar bag suppliers, not quotes.

3. Submit your layout. Strictly adhere to the dieline. Don't omit the bleed area between your design and the dieline.

4. Approve a proof. Print some and prototype with your product.

5. Place your entire order. Get your lead time in writing.

6. Check the shipment. Check color, seals, texture, the lot.

Checking it in that order saves you money, time and headaches down the line.

Novice Considerations

Selecting the wrong size - more often than you imagine.

Reliance on screen colors - print colors always change a bit.

Not checking seal quality - a poor seal = rotten goods.

Not factoring lead time in - custom runs take time.

Omitting legal inspections - food and cannabis labels contain compliance.

Small mistakes are costly lessons. Be careful in the first instance to save yourself the cost subsequently.

Final Thoughts

Branded Mylar bags printed express your brand voice before you say a word. They insulate your product, reflect your personality, and enable you to get repeat customers.

Test small, learn quickly, and grow incrementally. Each run is a learning process on its own, a size tweak, a finish change, an improved zip. Once you get the beat and a supplier who understands, each reorder is a walkover and stress-free.

Custom print mylar bags today!