Custom Pouches

Resealable Mylar Bags

Bespoke resealable Mylar Bags manufactured to order, with material and finish chosen around how the product ships.

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

No obligation

Start a quote

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 resealable mylar bags have to cope with

    Resealable Mylar Bags hold products the customer opens and closes repeatedly over the life of the pack. That is the starting point for the specification, because leave real headroom between the fill line and the zip. A resealable bag with no access room defeats its own purpose.

    In service they are used for snacks, coffee, pet food and anything used over days or weeks.

    Where resealable mylar bags are actually used

    Resealable Mylar Bags are specified for snacks, coffee, pet food and anything used over days or weeks. Leave real headroom between the fill line and the zip. A resealable bag with no access room defeats its own purpose.

    • Snacks, coffee, pet food and anything used over days or weeks
    • Coffee and dry goods
    • Snacks and confectionery
    • Supplements and powders

    The substrate for resealable mylar bags

    A press-to-close zip below a tear notch, so the bag is tamper-evident on first opening and resealable afterwards.

    The options we would consider for this format are below; leave real headroom between the fill line and the zip. A resealable bag with no access room defeats its own purpose.

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

    Holding resealable mylar bags before service

    The zip is placed too close to the fill line, so the customer cannot get a hand in without spilling.

    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 resealable mylar bags

    The zip band creases and the tear strip removes a strip of artwork. Design around both rather than through them.

    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 resealable mylar bags

    The zip band creases and the tear strip removes a strip of artwork. Design around both rather than through them.

    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 resealable mylar bags

    Any size, with the zip adding a small amount of height above the fill line.

    Send the contents rather than a box size. Headroom above the fill is trimmed to save film, and the bag becomes awkward to use exactly where it should be convenient.

    What we need from your files

    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

    Start with dimensions and quantity. If you already run something similar, a physical sample tells us more in a minute than a specification does in a page.

    You approve the quote, we send the dieline, prepress proofs it, and production follows. The proof stage is where changes are still free.

    Sampling before you order

    A plain structural sample is the cheapest way to find a fit problem — far cheaper than finding it across a full run.

    Sample costs are normally credited against the production order.

    Reference

    Resealable Mylar Bags at a specification level

    ProductResealable 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 Resealable 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

      Why buyers specify this format

      Sized to the contents

      Any size, with the zip adding a small amount of height above the fill line.

      What tends to go wrong

      The zip is placed too close to the fill line, so the customer cannot get a hand in without spilling.

      What it is specified for

      Specified for snacks, coffee, pet food and anything used over days or weeks.

      The detail that decides it

      Leave real headroom between the fill line and the zip. A resealable bag with no access room defeats its own purpose.

      This format sits in our custom pouches range, alongside 26 other made-to-order formats.

      Answers

      Resealable Mylar Bags: questions buyers ask

      Specification, minimums and lead times for resealable mylar bags.

      How much headroom should a resealable pouch have?

      Enough to get a hand or a scoop in above the fill line. Trimming it to save film is a false economy — a resealable bag you cannot reach into is worse than one without a zip.

      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.

      What do resealable 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 resealable 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 resealable 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.

      Can you hold the specification for repeat orders?

      Yes. Once a first run is approved we hold the board, structure, dimensions, print method and finishes against your account, so a reorder references the same specification exactly rather than being re-derived. It also means a reorder can be priced against a larger quantity without re-opening the specification.

      Next step

      Quote Resealable Mylar Bags

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