Min. 100 units · 3–5 days
Small Mylar Bags
Custom Pouches
Specify thisCustom Pouches
3.5 Mylar Bags built to your specification — your dimensions, your board, your print.
No obligation
Name, email, phone and what you are packing. Attach artwork if you have it. We reply with a specification and a written price, usually within one business day.
3.5 Mylar Bags hold a specific small fill — the 3.5g retail unit common in regulated and specialty categories. That is the starting point for the specification, because size to the settled volume, not the loose volume. A fixed-weight product in an oversized bag looks like short measure.
In service they are used for fixed-weight retail units where the customer knows exactly what weight they bought.
3.5 Mylar Bags are specified for fixed-weight retail units where the customer knows exactly what weight they bought. Size to the settled volume, not the loose volume. A fixed-weight product in an oversized bag looks like short measure.
A barrier laminate with a resealable zip, since these units are typically used across several sittings.
The options we would consider for this format are below; size to the settled volume, not the loose volume. A fixed-weight product in an oversized bag looks like short measure.
Product settles and the bag looks under-filled, which in a fixed-weight category invites complaints about short measure.
Paperboard also absorbs moisture from the air until it equalises with its surroundings. If stock sits more than about six weeks in unconditioned space, a moisture-resistant coating is worth its small premium.
The honest trade-offs between the stocks we would consider for this format.
| Material | Barrier | Recovery route |
|---|---|---|
| Uncoated kraft | None | Dry goods, short shelf life |
| Aqueous coated | Light moisture | Keeps paper recyclable |
| Foil laminate | Oxygen and moisture | Longest shelf life, not kerbside recyclable |
| Mono-material film | Good, shorter life | Store drop-off recycling |
Weight and compliance information dominate the panel in this category. Lay those out before the brand design.
Rotogravure, Digital film printing, Flexography are all available for this format. Run length usually decides which is cheapest: digital removes the plate cost on short quantities, offset and flexo overtake it at volume.
Weight and compliance information dominate the panel in this category. Lay those out before the brand design.
The finishes below are quoted line by line. Each is an additional pass, so dropping one is a real saving rather than a rounding difference.
Sized to a 3.5g fill, typically around 3 × 5 in with a modest gusset.
Send the contents rather than a box size. The bag is sized to the product loose rather than settled, so it looks half empty by the time it reaches a shelf.
Build artwork to the flat pouch dieline including the gusset panels, and keep barcodes on a flat face rather than across a seal.
Supply a print-ready PDF or vector file with fonts outlined and images at 300 dpi. Our prepress team checks every file before a proof is issued. On a pouch the check that matters most is that copy clears the seal areas, which are not printable.
Tell us what goes inside, how many you need and when. Those three answers are enough for us to specify and price the job properly.
A dieline template follows, sized to your product. Prepress checks your artwork against it and issues a proof; nothing runs until you sign that off.
We can produce a plain unprinted sample so you can check the fit and structure of 3.5 mylar bags before committing.
Sample costs are normally credited against the production order.
Reference
| Product | 3.5 Mylar Bags |
|---|---|
| Category | Custom Pouches |
| Construction | Pouch |
| Structure | Multi-layer laminated film |
| Barrier | Moisture and oxygen barrier available |
| Closure | Heat seal, optional resealable zipper |
| Materials | PET/MPET/PE laminate, Kraft paper/PE laminate, Clear PET/PE laminate, Recyclable mono-PE |
| Printing | Rotogravure, Digital film printing, Flexography |
| Finishes | Matte film, Gloss film, Soft-touch film, Spot gloss over matte, Metallised layer |
| Minimum order | Minimum order is 100 units on any format, and unit cost falls sharply as the quantity rises. |
| Lead time | 3 to 5 business days after artwork approval |
| Shipping | Across the US, UK, Canada and Australia |
Specification builder
Set what you know, leave the rest. Everything here travels with your request, so nothing gets retyped.
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In practice
Sized to a 3.5g fill, typically around 3 × 5 in with a modest gusset.
Product settles and the bag looks under-filled, which in a fixed-weight category invites complaints about short measure.
Specified for fixed-weight retail units where the customer knows exactly what weight they bought.
Size to the settled volume, not the loose volume. A fixed-weight product in an oversized bag looks like short measure.
This format sits in our custom pouches range, alongside 26 other made-to-order formats.
Answers
Specification, minimums and lead times for 3.5 mylar bags.
Because it was sized to the product loose rather than settled. Fill it, let it settle, then measure. In a fixed-weight category an oversized bag reads as short measure even when the weight is right.
It depends on shelf life and what degrades the product — oxygen, moisture or light. A higher barrier costs more and is usually harder to recycle, so the right answer is the lowest barrier that holds your product for as long as it needs to.
Not currently, and it is better to be straight about it. Multi-layer laminates block best precisely because they combine materials, which is what makes them hard to recycle. Mono-material films are recyclable through store drop-off but give a shorter shelf life.
Through store drop-off in many areas rather than kerbside collection. Mono-material polyethylene is the more recyclable option; mixed-material films generally are not. If recyclability is a stated claim, tell us and we will keep to a mono-material construction.
Both are standard options. A zip suits anything the customer opens repeatedly; a one-way valve is for products that off-gas, such as freshly roasted coffee, where a sealed bag would otherwise inflate.
3 to 5 business days after artwork approval, plus freight. Pouch runs with applied finishes can take longer because each finish is a separate pass, and we confirm a firm date in writing with the quote.
Prices start from $0.30 per piece for large-volume orders. For this format the biggest levers are quantity, print route, board grade and how many finishing passes are involved. We quote each element separately so you can see where the money is going. On this format the film structure and whether you need a zip or a valve move the price more than quantity does at small volumes.
Yes. We can send a plain unprinted sample so you can check the fit and structure, or a printed prototype for colour and finish. Sample costs are normally credited against the production order. A plain sample answers fit and structure; a printed one answers colour. On 3.5 mylar bags it is usually fit that is worth checking first.
Send the current specification or a physical sample and we will quote to match it rather than proposing an alternative you would then have to re-approve internally. A physical sample tells us more than a specification sheet — board caliper and coating are usually described loosely and measured exactly.
All 50 US states, the United Kingdom, Canada and Australia, on the same timeline everywhere: 3 to 5 business days of production after artwork approval, then 5 to 7 business days in transit. Every run is made to order and shipped directly to your address rather than pulled from stock, so you receive current production rather than whatever has been sitting in a warehouse. Freight is costed separately by weight, volume and destination. This format nests or lies flat, so a large quantity takes up far less freight volume than the finished pack suggests.
Every run is cut to your dimensions — there are no stock sizes here. Send the product measurements rather than a box size and we will build the pouch around them, then send a dieline template you can design onto.
We issue a dieline template sized to your product, prepress checks your artwork against it, and a proof comes back for sign-off. Nothing runs until you approve that proof, and pouches then take 3 to 5 business days.
Related formats
Next step
Send the dimensions and quantity you need. We reply with a full specification and a written price, usually within one business day.