If you are planning to package products in flexible packaging, one of the first questions you will ask is simple: how much do custom Mylar bags cost? The answer varies widely. Depending on size, quantity, quality, materials, thickness, printing method, and special features, prices typically range from about $0.04 per bag to $1.25+ per bag.
Average Cost of Custom Mylar Bags
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Ultra-high volume (100,000+ units): about $0.04 to $0.18 per bag
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High volume (10,000 to 100,000 units): about $0.08 to $0.35 per bag
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Mid volume (3,000 to 10,000 units): about $0.12 to $0.65 per bag
- Low MOQ custom orders (100 to 3,000 units): about $0.60 to $1.25+ per bag
What Affects Mylar Bag Pricing
1. Quantity
- The size of an order has the largest cost impact.
- The unit price of mylar bags goes down considerably with larger orders.
- The unit price of mylar bags becomes more expensive when ordered in small quantities.
- Manufacturers will create cost breaks at different quantity thresholds.
As an example, moving from 5,000 to 50,000 bags will reduce your per bag cost by nearly 50%.
2. Bag Size & Shape
The material used in a larger bag is more than that of a smaller bag, therefore your larger bags will cost more than smaller bags.
Popular shapes of pouches include:
- Flat Pouches
- Stand-Up Pouches
- Gusseted Bags
- Shaped or Die-Cut Bags
A Stand-Up Pouch with a bottom gusset will cost more than a flat pouch because it has more material in it, and requires more complex sealing than a flat pouch.
3. Material Construction & Thickness
All Mylar bags are not created equal.
A high-barrier multilayer film providing barrier protection to moisture, oxygen, and/or odor will be more costly than a standard material.
Barrier structures that require premium construction include:
- Food Products
- Herbs/Botanicals
- Gummies/Snacks
- Cosmetics
A thicker film will also add to the cost due to the additional durability.
4. Printing Method
Printing will have a significant impact on the cost.
Digital Printing
- Best for shorter production runs
- Lower Set-Up Costs
- Cost per unit is higher than gravure printing
Gravure Printing
- Best suited for long production runs
- Higher Set-Up Costs
- Lowest cost per unit at continued long runs
- Higher print quality than other printing methods
In the case where you only need a few thousand bags, digital printing will usually be the lowest price option.
5. Finishes and Add-Ons
Some premium finishes will increase overall cost but will give your product improved shelf appeal and/or functionality.
Some of the more common finishes which will add to the cost of Mylar Bags include:
- Matte Finish
- Soft-Touch Finish
- Spot UV Coating
- Holographic Effect
- Metallic Ink
- Clear Windows
- Resealable Zippers
- Tear Notches
- Hanging Holes
- Child-Resistant Closures
Each of these finishes will increase the complexity and costs of manufacturing a Mylar Bag.
"The cost of custom flexible packaging reflects raw materials, barrier performance, print complexity, order volume, and converting technology. Higher barrier laminates and detailed graphics increase unit cost, but they also improve product protection and brand presentation." - Dr. Susan E. Selke, Packaging Industry Specialist
Hidden Costs To Consider
There are other hidden expenses aside from the cost per bag. The following additional costs may need consideration when creating your total packaging budget:
- Graphic design expenses
- Printing cylinder cost
- Shipping/Freight cost
- Storage fees
Brands like Brandmydispo, offer free graphic design services, no plate fees, & free shipping.
By taking these items into account when creating your total packaging budget, you create a more accurate overall figure to base your packaging decisions on.
Ways to Achieve Best Prices for Custom Mylar Bags
There are a few things that can help you have lower packaging expenditures:
- Ordering in larger quantities.
- Using a less sophisticated design on the bags
- Avoiding multi-process finishes that aren't absolutely essential (such as spot UV).
- Using standard sizes for your Mylar bags.
- Plan ahead, avoiding the need for rush shipments arrives
When selecting packaging, especially custom mylar bags, the balance between your company's desired branding image vs. cost is extremely important.
Summary Thoughts
Custom Mylar bags can cost anywhere from $0.04 to $1.25+ per unit, depending on quantity, size, quality, materials, printing, and features. Businesses ordering in bulk benefit from dramatically lower prices, while small orders prioritize flexibility over cost efficiency.
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