Many wonder "How do you print mylar bags?" To print Mylar bags, use a die-line template, then use digital printing for short runs or rotogravure for large volumes. The film is corona-treated, printed, laminated to protect the ink, and heat-sealed into finished bags.

Demand for the custom printed Mylar bag is growing rapidly because companies now see their packaging as not only protection but also a very effective marketing tool; in fact, studies indicate that 72% of consumers base their product choices on the packaging alone. No matter if you are in the food, canna, or cosmetics industry, using top-quality printing on your Mylar pouches will help to increase both shelf appeal and brand recognition. This guide will outline everything you need to know about printing Mylar bags, including initial designs through final production.

What we will discuss:

1. How mylar bags are printed.
2. What printer are used to print mylar bags.
3. Step by step guide on mylar bag printing.
4. Common made mistakes when printing.

Mylar Bags: What Are They?

Mylar is actually just a trade name for BoPET (Biaxially-Oriented Polyethylene Terephthalate), which is a type of polyester film that has excellent strength and barrier properties. Mylar bags are usually made from a combination of multi-layered laminated films (polyester, aluminum foil, etc.) and that’s how they are so good at keeping their contents fresh.

Benefits of Using Mylar Bags for Packaging:

1. Barrier Protection: Mylar blocks 99.9% of O2 and light, and provides excellent moisture barriers, which helps prolong the shelf life of items such as coffee, snacks, and dry goods.

2. Durability: They do not tear or puncture easily and can withstand extreme temperatures (- 70° F to + 300° F).

3. Weight Savings: Switching from glass containers (like jars) to Mylar bags can reduce shipping weight by as much as 30%.

4. Excellent Printing Surface: Mylar’s non-porous and smooth surface allows for high-quality printing and attention-grabbing graphics.

How are Mylar Bags Printed?

Specialized flexible packaging techniques are used to print the artwork on Mylar Bags (eg., a rotogravure printer or a digital printer), before the Mylar bags have been formed and sealed. The artwork starts as a print-ready file (ready to print), then these images are printed onto multiple layers of polyester and polyethylene that have been laminated to provide durability and barrier protection. For smaller runs of Mylar bags, digital printing presses are often utilized, while larger runs use gravure printing to provide better quality and lower cost per unit.

Mylar Bag Printing Methods

There are various methods available for printing onto Mylar; which one is the most appropriate depends on your budget, how many items you'll be printing, and how intricate the artwork/design will be. Below are the options that packaging companies prefer to use when printing onto Mylar:

1. Digital Printing
If you are looking for an easy, modern, and flexible way to print your designs on mylar, digital printing is your best option. Digital printing is a high-end office-style printing process, so your design is printed digitally straight onto the film without using any printing plates.

- Best Use: Digital printing is perfect for new businesses and start-up companies, as well as short runs, product testing, seasonal designs, and multiple design products (like SKUs) within one run.

- Digital Printing Pros: Fast turn-around times of 7 days or less, no plate costs, LOTS of design variables, high-quality images with extremely bright and saturated colors, etc.

- Digital Printing Cons: The cost per unit for large quantities will be more expensive than other methods.

2. Rotogravure Printing
Rotogravure is the 'king' of the high-volume/high-quality printing industry. The images/designs for rotogravure are etched into numerous cylinders and the ink is applied to the film by running the film over the cylinders. This type of printing creates some of the deepest colors and the most detailed images.

- Best Use: Rotogravure is most effective for large runs with quantities of 10,000+, due to the fact that the initial setup (etching the cylinders) is spread across this large number of products.

- Rotogravure Pros: The lowest cost per unit on large quantities (over 10,000 pieces); the best overall color saturation and consistency; and the best printing method for highly complex and luxurious print designs.

- Rotogravure Cons: The initial costs to etch the cylinders are extremely high, the lead times are typically very long, and a design change means you will need to etch new cylinders, which will be another high initial cost.

3. Flexographic Printing
Flexographic printing uses raised polymer plates and is an extremely versatile and efficient method of printing. Each color for your design requires its own printing plate, and the film is run through each plate to create an entire image of your design.

- Best Use: Flexographic printing is best for medium to large runs of products, as it balances cost and quality.

- Flexographic Printing Pros: Faster and less expensive than Rotogravure for mid-sized orders; creates vibrant and sharp images.

- Flexographic Printing Cons: Plates must be made for each print run, and therefore there is an initial cost, as well as longer setup times. It is not usually a cost-effective method for short runs.

How to Print Mylar Bags: Step by Step Guide to Follow

Printing Mylar bags isn't easy; it's a complex process with many steps that occur prior to the creation of Mylar bags. Below is an example of a workflow that is generally followed by manufacturers.

1. Design and Prepress

The first step in producing a printed Mylar bag is to create your artwork on a mylar bag template. To create the best possible printed product, you need to use high-resolution (300 DPI+) vector files [such as .AI, .EPS, .SVG, or .PDF]. Your artwork needs to be in the CMYK color space and you will also need to include bleed areas and safe zones based on your suppliers die cut line in order to ensure that no important elements such as text or logos will be cut off when the bags are formed.

2. Plate/Cylinder Making

Depending on the printing method used, either flexible plates (for flexography) or engraved cylinders (for rotogravure) will be made for the production of Mylar bag. This step is the primary cost driver for setting up these traditional printing methods. If digital printing is being used this step is completely omitted.

3. Printing on Film

Printing occurs on the flat Mylar web (film roll) prior to lamination and cut of the film. The film passes through the press and layers of ink are applied precisely to the film as it passes through. For both digital and UV printing the ink is applied directly to the Mylar film and immediately cured either by heat or UV light. In order to ensure that the ink adheres properly to the glossier Mylar surface, a process called corona treatment is often used. In this process, the film is electrically charged in order to improve the bond of the ink.

4. Laminating

Once the film has been printed, it is commonly laminated with other materials (typically a sealant layer of PE) in order to protect the printed ink; create barrier properties; and provide the bag with its final structure. This laminate layer(s) effectively encapsulates your design between layers and ensures that the graphic does not peel or scratch off.

5. Manufacturing Bags (Converting)

The laminated/printed roll is sent to a pouch making machine that converts the roll into a finished Mylar bag by folding the film roll, building gussets into the bag, adding features (such as zipper or tear notches), and heat sealing the edge of the bags to produce the completed Mylar bag.

6. Quality Control

All batches of Mylar bags are subjected to inspection for color accuracy, registration (color alignment), seal integrity, and overall durability to ensure premium printed product.

Design and Customization Choices

Among several benefits custom printing Mylar Packaging has is the numerous finishing options available to augment your design and help make a strong impression while sitting on store shelves.

Enhance your product packaging with a number of popular finishes, including:

Gloss versus Matte finish - A gloss finish has a very bright, lustrous appearance, whereas a matte finish has a more sophisticated, non-reflective quality, and fingerprint resistant.

Spot UV Gloss - Spot UV is a high gloss coating applied to specific portions of your design (like a Logo) for visual effect, enabling them to pop on a matte background.

Foil Stamping - Using Gold or Silver Foil stamping adds a premium, shiny metallic to your packaging.

Embossed/Debossed - Embossed (raised) or Debossed (indented) texture can produce a high-quality Premium tactile feel to your bags.

Functional additions to consider include:

• Resealable zippers (child-resistant options available)
• Easy to tear Notches for opening
• Degassing valves for Coffee
• Hang holes for retail display purposes
• Clear transparent windows
• Spouts for liquid filling

Commonly Made Printing Mistakes

Printing custom packaging is expensive. Avoiding some common mistakes will help create a successful printing project with your manufacturer.

1. Using low-resolution image files - Low-resolution image files can result in an unprofessional appearance because images can appear blurry or pixelated; therefore, always submit high-resolution vector images.

2. Ignoring the template - If you do not follow the manufacturer’s Dieline template, you could eliminate or cut off critical parts of your design or have elements of your design extend into an area that will be sealed during packaging.

3. Not approving a proof - Required before production begins; always ask for and review either a physical sample or a high-resolution digital proof before providing your final approval. Pay close attention to review colors, text, and alignment.

"Polyester films present relatively low surface energy, which can limit ink adhesion without treatment. Surface modification processes such as corona or plasma treatment improve wettability and allow inks to anchor properly." - Dr. Edward D. Petrie, Polymer Adhesion Specialist

So, How Do You Print On Mylar Bags?

To print Mylar bags, you must create a print-ready design file, then have the artwork applied to Mylar film using digital or rotogravure printing before the material is formed and heat sealed into bags. Small batches are typically printed digitally, while large quantities use rotogravure for higher quality and lower cost per unit.

Wrapping it Up

Creating custom printed Mylar bags is a complex combination of material identification and printing technology, and by knowing which printing methods are best suited for your project, such as Digital and Rotogravure, you will have the ability to create a package that gives your product protection and elevates the identity of your brand.

Working with an experienced mylar bag manufacturer, who can assist you with design, material selection, and printing, will ensure your finished custom printed Mylar bags look as good as you want and will have the durability to protect what you put in them.