Custom Pouches

3.5 Mylar Bags

3.5 Mylar Bags built to your specification — your dimensions, your board, your print.

Minimum order
100 units
Production
3–5 business days
Construction
pouch
Delivery
US, UK, Canada, Australia

No obligation

Get a price

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.

The more detail you give, the more accurate the quote.

Drop files here or browse

PDF, AI, EPS, SVG, PNG, JPG, WEBP or ZIP. Up to 5 files, 10 MB each.

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    What 3.5 mylar bags have to cope with

    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.

    Where 3.5 mylar bags are actually used

    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.

    • Fixed-weight retail units where the customer knows exactly what weight they bought
    • Coffee and dry goods
    • Snacks and confectionery
    • Supplements and powders

    The substrate for 3.5 mylar bags

    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.

    • PET/MPET/PE laminate
    • Kraft paper/PE laminate
    • Clear PET/PE laminate
    • Recyclable mono-PE
    • Compostable kraft/PLA

    Holding 3.5 mylar bags before service

    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.

    Comparing the substrate options

    The honest trade-offs between the stocks we would consider for this format.

    MaterialBarrierRecovery route
    Uncoated kraftNoneDry goods, short shelf life
    Aqueous coatedLight moistureKeeps paper recyclable
    Foil laminateOxygen and moistureLongest shelf life, not kerbside recyclable
    Mono-material filmGood, shorter lifeStore drop-off recycling

    Printing 3.5 mylar bags

    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.

    Finishing 3.5 mylar bags

    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.

    • Matte film
    • Gloss film
    • Soft-touch film
    • Spot gloss over matte
    • Metallised layer

    Sizing 3.5 mylar bags

    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.

    Getting artwork press-ready

    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.

    How an order runs

    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.

    Sampling before you order

    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

    3.5 Mylar Bags at a specification level

    Product3.5 Mylar Bags
    CategoryCustom Pouches
    ConstructionPouch
    StructureMulti-layer laminated film
    BarrierMoisture and oxygen barrier available
    ClosureHeat seal, optional resealable zipper
    MaterialsPET/MPET/PE laminate, Kraft paper/PE laminate, Clear PET/PE laminate, Recyclable mono-PE
    PrintingRotogravure, Digital film printing, Flexography
    FinishesMatte film, Gloss film, Soft-touch film, Spot gloss over matte, Metallised layer
    Minimum orderMinimum order is 100 units on any format, and unit cost falls sharply as the quantity rises.
    Lead time3 to 5 business days after artwork approval
    ShippingAcross the US, UK, Canada and Australia

    Specification builder

    Specify 3.5 Mylar Bags in under a minute

    Set what you know, leave the rest. Everything here travels with your request, so nothing gets retyped.

    • 100-unit minimum
    • 3–5 day production
    • Free dieline
    • No obligation
    Approximation only — proportions, colour family and finish character. Not a colour proof, and the panel shown is a placeholder, not your artwork.
    Packaging type
    Box style
    Quantity
    Colour
    Material
    Printing
    Finish

    Drop files or browse

    Up to 5 files, 10 MB each.

      Prices start from $0.30 per piece for large-volume orders. Final pricing depends on size, material, printing, finishes, and quantity.

      In practice

      What you get with this format

      Fitted to what goes in it

      Sized to a 3.5g fill, typically around 3 × 5 in with a modest gusset.

      The failure we design out

      Product settles and the bag looks under-filled, which in a fixed-weight category invites complaints about short measure.

      Where it has to work

      Specified for fixed-weight retail units where the customer knows exactly what weight they bought.

      The detail that matters

      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

      3.5 Mylar Bags: questions buyers ask

      Specification, minimums and lead times for 3.5 mylar bags.

      Why does my 3.5g bag look half empty?

      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.

      What barrier do I actually need?

      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.

      Can I have a full barrier and full recyclability?

      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.

      Are poly formats recyclable?

      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.

      Can you add a resealable zip or a valve?

      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.

      How long do 3.5 mylar bags take to produce?

      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.

      What do 3.5 mylar bags cost?

      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.

      Can I see a sample first?

      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.

      Can you match packaging we already use?

      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.

      Where do you deliver?

      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.

      Can I order 3.5 mylar bags in a custom size?

      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.

      What happens after I approve the quote?

      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.

      Next step

      Get a price for 3.5 Mylar Bags

      Send the dimensions and quantity you need. We reply with a full specification and a written price, usually within one business day.