Custom Pouches

Small Mylar Bags

Small 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

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 small mylar bags have to cope with

    Small Mylar Bags hold single servings, samples and small high-value quantities. That is the starting point for the specification, because leave a clear seal zone above the fill. At small sizes that margin is proportionally larger than instinct suggests.

    In service they are used for samples, single-dose products and small high-value goods.

    Where small mylar bags are actually used

    Small Mylar Bags are specified for samples, single-dose products and small high-value goods. Leave a clear seal zone above the fill. At small sizes that margin is proportionally larger than instinct suggests.

    • Samples, single-dose products and small high-value goods
    • Coffee and dry goods
    • Snacks and confectionery
    • Supplements and powders

    The substrate for small mylar bags

    A standard laminate; gauge matters little at this size because handling loads are small.

    The options we would consider for this format are below; leave a clear seal zone above the fill. At small sizes that margin is proportionally larger than instinct suggests.

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

    Holding small mylar bags before service

    Filling. At this size the seal area is proportionally huge and it is easy to trap product in it, which prevents a clean seal.

    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 small mylar bags

    Very little area. A single mark and the required information will fill it — plan for that rather than a full 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 small mylar bags

    Very little area. A single mark and the required information will fill it — plan for that rather than a full design.

    Finishes are costed one at a time because each is a separate operation — that way you can see which one is carrying the price.

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

    Sizing small mylar bags

    From around 2 × 3 in through 4 × 6 in, where the seal area is large relative to the fill.

    Send the contents rather than a box size. The bag is sized to the contents exactly, leaving no clear seal zone above the fill.

    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.

    What we need from you

    The useful starting point is the product, not the pack. Give us its measurements and the quantity, and we work the pouch outward from there.

    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

    Ask for an unprinted sample if the question is fit, or a printed prototype if the question is colour. They answer different things.

    Sample costs are normally credited against the production order.

    Reference

    Small Mylar Bags at a specification level

    ProductSmall 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 Small 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

      Getting the dimensions right

      From around 2 × 3 in through 4 × 6 in, where the seal area is large relative to the fill.

      The failure worth avoiding

      Filling. At this size the seal area is proportionally huge and it is easy to trap product in it, which prevents a clean seal.

      Where it is used

      Specified for samples, single-dose products and small high-value goods.

      The detail that decides it

      Leave a clear seal zone above the fill. At small sizes that margin is proportionally larger than instinct suggests.

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

      Answers

      Small Mylar Bags: questions buyers ask

      Specification, minimums and lead times for small mylar bags.

      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.

      Is there a minimum size you can produce?

      Small formats are limited by what the die and the gluing line can hold rather than by any policy. Small Mylar Bags sit comfortably within that, but tolerances tighten as size drops, so we recommend a structural sample before print.

      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.

      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 file format should I send artwork in?

      A print-ready PDF or a vector file, with fonts outlined and any raster images at 300 dpi at final size. We supply the dieline to design onto, and prepress checks bleed, safe area and crease clearance before issuing a proof. The dieline we supply carries the crease positions, so keeping type clear of a crease is easier to solve at layout than at proof.

      What is the minimum order for small mylar bags?

      A flat 100 units on any format. Most pouches in this range are quoted from 100 units upward because unit cost falls sharply above that, but the minimum exists so you can validate a structure first.

      How long do small 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 small 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 small 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. Small formats consolidate well, so if you are ordering several at once they normally travel as a single consignment rather than being charged separately.

      Next step

      Get a price for Small Mylar Bags

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