What Really Happens Before a Mylar Bag Ever Hits the Shelf

A Mylar bag undergoes a complicated process involving many steps before it arrives in the store. Often, folks believe that the artwork is put onto the bag and then sealed; however, there are multiple steps where items are built upon one another as the production continues. Skipping anything along the way can lead to difficulties later in the process.

The first step in creating a Mylar bag is creating the artwork digitally on a computer. The colours must be changed depending on how reflective or opaque the Mylar will be when printed, and on how much ink the Mylar will absorb. What we perceive to look "perfect" on a digital screen may not print well on Mylar unless it has been optimised correctly for use in a Mylar bag. This is where the printer's extensive experience will make the largest impact on finished products made from Mylar.

Also, there are different printing methods available to create Mylar bags, which will affect the overall quality and ability to mass-produce your product. Digital printing offers the quickest and greatest amount of versatility with respect to the number of items produced. Rotogravure printing offers the best quality and consistency for those products that require an extremely high volume of product with exact colour consistency across the entire run. Flexographic printing allows for a combination of good quality and good quantity while also delivering an item that has a simpler design.

One of the most important parts of the mylar bag printing process is the layering of the inks that were used to print the artwork. White ink is often printed below all of the other colours to control the brightness and opacity. If your artwork does not have a white ink base, the colours will look very dull and uneven. This process provides brands with a solid opportunity to produce and maintain colours consistently on all packaging that uses multiple finishes, bag styles and designs across many different types of bags.

Once the printing process is completed (to design) and the bag has been laminated, the design becomes protected and the feel of the bag will actually be changed from what it would normally feel like without the lamination. Lamination protects the print from scratches, moisture, etc., while also extending the life of the print (to ensure that it looks good after many months of use). Lamination also contributes to the overall feel (whether a package feels stiff or flexible) that a customer has when they are considering purchasing a Mylar bag.

This guide explains the life cycle of a typical Mylar bag from the beginning until the bag is completed for use, along with why the explanation is very important and provides a good educational reference for anyone who is looking to create their own custom packaging.