How to Customize Mylar Bags: The Complete Guide

Customized Mylar bags are the most popular type of modern product packaging and are used by businesses to package everything from snacks and supplements to coffee, personal care items, and other retail items in a way that protects the product, extends shelf life, and provides enough appeal to turn shoppers into buyers. To create custom Mylar packaging, it is important to learn how to custom made Mylar bags to look professional, maintain freshness, and establish trust in your brand.

This complete guide outlines each step of the process of creating custom Mylar bags, including what materials are used, how they are printed, how to determine what the bag size should be, what regulations must be followed, and how to design a proper bag that functions properly and looks good.

What Are Custom Mylar Bags?

The material used to make Mylar bags is a flexible, high-barrier pouch manufactured from a specially-treated poly-ethylene terephthalate (PET) film that is layered with other films including aluminum foil and other types of polyethylene. They function as barriers to moisture, oxygen, light, and other contaminants, so they are widely used for food storage, retail packaging, and long-term food preservation.

Customizing Mylar bags means modifying the size, shape, thickness, finish, and printed design to fit your product and brand identity.

Step 1: Determine Which Style of Bag Is Right For You

The process of customizing a Mylar bag begins with choosing the correct bag type for your product. The type of bag you choose to use is determined by how you will use your product, and how your product will look when displayed on a retail shelf.

Some of the most popular styles of Mylar bags:

– Stand up pouches (doy packs) for display on retail shelves

– Flat pouches for lightweight goods

– Side gusset bags for larger products

– Three-side seal pouches (single serve)

– Child-resistant pouches (for products that fall under regulation)

– Spout pouches (for liquids and gels)

If your product needs to be displayed upright, using stand up pouches with bottom gussets is ideal. If you want to conserve space and reduce shipping costs, flat pouches may be your best option.

If you are unsure which style fits your product, reviewing actual custom Mylar bag options can help you compare structures and capacities in real world use.

Step 2: Select the SIze

Size is often a little known factor when designing printed Mylar bags. A custom bag that is too big will waste material and look unprofessional. A custom bag that is too small could damage the product or impair the seal.

Factors that determine size include:

– Product weight and volume

– The shape of the product being placed inside the bag

– The amount of headspace needed above each product before sealing the bag

– How the products are displayed at retail

For example, lightweight dry foods will require more interior space than dense dry foods of the same weight.

Step 3: Choose The Thickness & Material

Mylar bags are available in thicknesses measured in mils. Thicker mil materials have the ability to withstand more abuse and provide a higher level of protection.

The most common thicknesses found in Mylar bags include:

– 3.5 to 4 mil for light-weight products;

– 5 to 5 mil for standard retail products;

– 7 mil and better for heavy or pointy products.

Barrier property requirements are determined based upon the product type. For example, food products will generally require high levels of barring for moisture and oxygen, whereas a product that is non-perishable and will not naturally deteriorate will generally not require high-level barring.Fourth Step: Choosing Finishing and Appearance

Once you enhance your product’s appearance, you can also turn it into a marketing tool.

Available Finishing Options are:

1. Matte Finish – Contemporary, luxury look

2. Gloss Finish – Bright contrast and shine

3. Soft Touch – Upscale touch

4. Holographic – Provides depth with an optical illusion

5. Foil – High-impact finishing type for your brand

6. Clear Windows – To showcase your product

Using different finishing techniques, e.g. matting and spot gloss, will also create a two-tone look that makes your logo or artwork stand out.

Step 5: Customizing for Functionality

Modern printable Mylar bags can also provide you with modern features to make it easier for the end-user to use the bag. They must also comply with all of the various legal requirements.

Available Add-On Functionalities:

1. Resealable Zippers

2. Tear Notches

3. Hanging Holes

4. Valves for Coffee Packaging

5. Child Resistant Closures

6. Tamper Evident Seals

Using the latest functionality features available to your packaging will positively impact your customer’s experience and provide the best possible protection for your product.

Step 6: Maximum Impact Through Visual Artwork Design

Visual design of the packaging is very important for brand recognition and conversion.

Elements of Good Design:

1. High-Resolution Artwork/Graphics

2. Standard Decimal Size Fonts/Type

3. Clear Packing Information

4. Legal Davidson’s

5. Use Approved Brand Colour Schemes

Packaging should directly tell a customer what the product is and why it is important and reassure them about the product.

Step 7: Choose Your Printing Method

Different printing options can affect the costs, colours, and amount of each type that you can order.

Some Common Printing Processes:

1. Digital: Best for Short Runs and Quick Turn Around, digital printing has the ability to produce high-end graphic quality without needing printing plates.

2. Gravure: Best for Long Print Runs, Gravure printing produces highly durable and consistent colour and delivers the best extreme colour consistency

3. Flexographic: Economical for Medium Print Runs (and larger) using very few colors.

Step 8: Validate Product Compliance with Accurate Labelling

Certain industries require all products to be labelled in a specific manner (e.g. specific warning labels or regulatory disclosures). Food packaging, supplement packaging, and any other regulated packaging must also comply with all laws relating to product contents and safety.

Make sure to verify that all of the following meet the requirements of the law:

1.Nutritional Information

2. List of Ingredients

3. Barcode

4. Safety Warnings

Failing to do so could result in costly recalls or other legal issues.

Step 9: Sample Test Prior to Mass Production

By ordering samples of your packaging, you can assess all of the physical attributes associated with your product packaging:

1. Print Quality

2. Colour Accuracy

3. Material Durability

4. Seal Quality

5. Overall Appearance

Testing samples to assess product packaging will greatly reduce the risk of ordering massive quantities of product that do not meet production expectations.

Step 10: Optimize for Branding and Marketing Objectives.

As an alternative sales tool, packaging can be a great resource.

Customizing packaging properly can provide:

1. Increased perception of value

2. Improved brand recall

3. Differentiate your product from the competition in a crowded category

4. Build confidence in your brand with consumers.

Brands that invest in packaging also have higher conversion rates and are able to cultivate more brand loyalty.

The Importance of Printed Mylar Bags to Establish Brand Authority

Customized packaging conveys a sense of professionalism, reliability, and quality to customers. Using customized packaging establishes your brand and conveys that you are an actual business. In many instances, a consumer’s purchase decision will be based on product packaging compared to your competitor’s.

Final Thoughts on Customizing and Branding Mylar Bags.

Customizing your Mylar bags is a project that takes into consideration principles of Material Science, Design, Brand Equity, and Consumer Behaviour. By strategically deciding about style, size, thickness, finishes, features, and printing type of your custom Mylar packaging, you now have packaging that protects the product inside your Mylar packaging (whatever it is) and also enhances your brand.

When executed properly, customized Mylar bags won’t be just a structural container; they will be an excellent marketing tool that will generate excess revenue, increase your brand recognition, and build consumer confidence.