Posts

Why the “Right Size” Mylar Bag Rarely Feels Like a Coincidence

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  Externally speaking, the majority of the time, packaging choices appear random; however, they are almost always deliberately chosen. One aspect (size) is an example of one such choice that generally is evident after the fact. Before a product's size is determined, there is quite a bit of silence to be solved before a decision is made. If you are too tight, there is a sense the product has been stifled; if you are too loose, there is a sense that there is something missing. Examples of smaller size packaging would be 3 x 4 inches and 3.5 x 5 inches with the emphasis on control over the quantity of product contained. There is only enough product for one item. This is true for many products that are manufactured and sold each day. There are no wastes or excesses, which results in a more "intentional" feeling or connection to the consumer. The mid-size options of 4 x 6 inches and 5 x 8 inches work on a different level/rhythm, but are used more frequently than the smaller si...

Balancing Cost, Flexibility, and Growth in Packaging Orders

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All packaging decisions are based on trade-offs. Cost, Flexibility and Scalability. There isn’t a way to maximize all three simultaneously. With regard to custom mylar bags, quantity ordered is where those trade-offs start to become actualized. When you order in larger quantities it increases the more your cost per unit goes down; however, the larger quantity of bags also creates reduced flexibility since once the bags are printed, they are locked into the same design and size that carry the same version of your brand when printed. If your branding ever changes, you are going to have to work around your packaging instead of having your packaging working with you. The opposite of this is ordering in smaller quantities allow for a more flexible approach. A brand is able to adjust the bags with their design, enhance their branding or change the product they are selling without being burdened by holding excessive inventory. Conversely, the greater cost per bag can cut into your margins if ...

The Small Packaging Decision That Changes Everything

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  We often undervalue packaging; I mean, a bag is simply a bag; right? However, the bag serves as one of the first interactions that a potential customer will have with your brand and depending on which bag type you pick, the interaction can be smooth or can feel slightly…off. When considering the real-world performance of bags, within the categories of stand-up pouches, stand-up pouches hold their shape well when filled, are very visible and stable even after they have been opened a few times. This type of stability creates a subtle impression of quality even if no two customers would be able to articulate why. Conversely, flat pouches create an entirely different situation. They weigh less; they stack well for storage; and they have an efficient design for shipping. However, they will never provide the same level of presence on a shelf. That is fine for a great number of products, but for some products, they will reduce the visibility of the product and this will happen before an...

How Long Will Food Last Without a Proper Seal?

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  Most people spend their time considering what is put into Mylar bags. However, many don’t spend nearly enough time considering how they are closed – and that one simple detail can completely change the length of time your food lasts for! If a seal doesn’t work as it should be, the shelf-life is unpredictable! Many individuals may think they will be able to store food for years or many months, only to discover unexpectedly that the item(s) aren’t fresh, still soft, and/or have degraded before anticipated. Air is the biggest issue. Oxygen is what contributes to spoilage, even with dry food. If air is gradually leaking into the Mylar bag, it is beginning to break down the items at a molecular level. Changes to the texture occur first, then changes in the flavour, and eventually changes will be evident in the entire quality of the item(s). And by the time you are able to visually see changes, it is usually too late. Moisture is an additional silent issue. Even if you live in a dry en...

The Difference Between Smart Storage and Overengineering

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  The difference between being prepared and overengineering something is very thin. The line between the two becomes very blurry with food storage, because what may start out as a simple solution may quickly become an accumulation of “just in case” decisions. For example, I use mylar bags, oxygen absorbers, and in some cases desiccants, each one of those items has an individual purpose. When used together, without understanding how they work with one another, things can get. . . well. . . a bit off. Not broken, but inefficient in a way that you don’t realize until it’s too late. The primary culprit of this phenomenon are oxygen absorbers, which are extremely powerful; however, they are often not used correctly. Many people make the assumption that they should fill all of the open air space of a bag with as many absorbers as possible; however, this is incorrect because there is only a certain amount of oxygen in a given volume of air. Therefore, if you put too many absorbers in a ba...

How Consumer Behavior Is Quietly Changing Mylar Bag Design in 2026

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  Consumer behaviour does not change suddenly; it is a gradual process that starts with small changes, then eventually builds into something completely different. This is what's currently happening with custom Mylar bags. People now have different ways of interacting with packaging than they did before, and if brands don’t take note, they could be in trouble without realising why. One of the key shifts in behaviour is shorter attention spans and higher expectations from consumers. People are making split-second decisions, and at the same time, expecting much more from what they purchase. This means brands must create packaging that will ‘hit’ quickly and hit often. Whereas the average person used to give a product five seconds before determining whether or not to buy it, today the average amount of time is down to one second. If nothing resonates immediately with a consumer, chances are the ’hit’ product will be missed altogether. Along with this behaviour, there is a growing deman...

Why More Brands Are Prioritizing Innovation in Custom Mylar Packaging

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  Packaging was once simply functional, had to hold product, and not fall apart; with the exception of appealing for a part of the time. Today, brands are focusing greater emphasis on the need for innovation in packaging products because they are competing more crowded marketplaces. Therefore, if a product appears generic it will generally be treated accordingly; i.e., whether or not it deserves. Innovation can take many different forms with custom packaging. Some of the forms include visual innovations (such as inscriptions or printing technologies), functional innovations (such as closures and child-resistant designs), and physical innovations (such as building and maintaining the best version of the product). The best custom packaging suppliers are not offering the same old, stale formats that they did last year. They are truly focused on what brands need today, rather than what sold well three years ago. Flexibility is another significant aspect of innovation and particularly i...

Why Do Mylar Bags Feel Different Than Normal Plastic?

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  When you pick up a Mylar bag, you will most likely notice that it feels very different from the simple plastic bags your used to— when compared side by side the differences of texture and feel, stiffness, thickness, and overall feel are apparent. This is caused by how the bags are manufactured. Standard plastic bags have a fairly simple manufacturing process and are often manufactured from low strength plastic materials and simply designed for carrying or storing items. While Mylar bags are made from many different forms of higher strength materials built especially for their high performance manufacturing process. Therefore, the way in which the bag feels when you hold and the way the bag performs after you have filled it and sealed it will greatly differ from the standard plastic bags. In regards to packaging, if a bag has a sturdier feel it will often create a more professional impression on a customer and will protect the product better. Regardless of the product, such as cof...

Why Moisture Is the Real Enemy of Dry Goods

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  When you think of storing food for an extended period, your first thought is usually about expiration dates. While this is understandable, it’s usually not the number one problem we have to worry about with dry goods. More often than not, the true issue lies in the humidity and moisture getting to the product and causing clumping or hardening. This is why the way we package and/or store the product is very important as a method of preservation and not just as a method of presentation. A weak container will hold something, but it’s not necessarily going to hold it safely from humidity or moisture. The goal of better barrier-type packaging is to keep dry goods dry - plain and simple. This ensures that everything else associated with the item and using it will be easy. Using Mylar when packaging dry goods is becoming very popular because of the strength of the barrier it provides compared to other methods of storage. It’s light weight, easy to seal, and easy to store in bulk when cr...

Best Packaging Features for Dry Milk and Powdered Food Products

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  Not all powdered food bags will be adequate for your purpose, powdered milk may seem easy to package, but when selecting a bag, freshness, shelf life, re-sealability, storage conditions and proper material are extremely important. Choosing the right packaging features has just as much impact as the type of material used. One of the most significant features is barrier protection. Dry milk needs protection from moisture, light, odor and oxygen, EVA bags, with their UV barrier, will protect dry milk from moisture, odor and oxygen for a good amount of time. If the packaging leaks, the product can spoil or diminish in quality before you realize it. A stronger barrier bag will help to keep dry milk in good condition for a longer shelf life. Another very important feature is seal ability. Seal-able bags can be heat sealed for long term storage, but many brands as well as households want to have a Zip Top option for convenience after the product has been opened. Therefore, by combining ...

Why Product Packaging Matters More Than Most Brands Think

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  Many companies will put all their resources toward producing an exceptional product; the only problem is they do not give enough thought to the style or presentation of their packaging as part of their overall product experience – this could turn out to be a costly mistake. The first thing a customer sees when they open your product is the packaging; the way your packaging looks is often the basis for a customer’s perception of your entire product even before they use it. How you package your product can build customer confidence in you and your company; however, if you have poorly packaged your product, you risk losing customers based solely on how that packaging performs. Packaging becomes even more important in competitive industries where customers have a lot of options to choose from and where those options may appear very similar. If one option has an appearance that is cleaner, fresher, or more upscale than another option, the former option is likely to be the first choice...

How to Make Your Packaging Look More Professional

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  A lot of packaging looks homemade because it is over the top. Too many colors and fonts, too many words, too many effects. When every feature tries to steal the spotlight from another, the overall feel of the design becomes messy rather than professionally done. If you want your packaging to look professional, you don’t typically achieve this with more. You accomplish it with smarter design decisions upfront. The simplest method of creating a more elevated look for packaging is simplifying the front. The majority of successful packaging designs rely on 3 main ‘essentials’ only, which tend to create that upscale feel: the brand name; the product name; and an attractive visual direction to create that connection to the customer. The right amount of spacing and hierarchy generally adds to this upscale appeal more so than how the product was designed with complex art. Typography also has a key contribution toward whether or not a package has that upscale appeal or looks inexpensive. ...

Are Cheap Mylar Bags Worth It? What You Risk Saving Pennies

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  At first glance, using cheaper Mylar bags seems to make a lot of sense: lower price, easier to get into, less of a commitment to use them. On paper this seems to be a smart decision but once you start seeing the reality of how much you have lost out on…you start feeling dumb. Typically the first thing you will lose on with Cheaper Mylar bags is the quality of the material. Thinner films, weaker seals, and less effectiveness of your barrier protection will cause issues. These will not always show themselves, which make it worse because you won't know about the issues until after your product is outside of your control. Next you will start to lose the durability of the bag. Bags that tear and fail from being “over-pressured” not only create inconveniences for you but create a loss of trust in the customer. Customers do not separate the packaging from the product, for them it is ONE complete experience (like it or not). You will usually see a noticeable loss in printing as well. Col...

Why Sublimation on Mylar Bags Isn’t Always Straightforward

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  Sublimation seems magical on first glance. You press ink into a surface, heat it, and poof — it sprays on the surface as if it were there all along. No cracking, no peeling, and no funky textures. But then Mylar shows up, and it kind of ruins that whole fantasy. People are always asking the question “Can You Sublimate on Mylar Bags?” But the answer to that question is not a clear-cut yes or no; it’s more like an occasional yes — but only if everything comes together just right. Mylar is not the same as cotton or coated polyester, which are both great for sublimation. Mylar has a lot of different layers and is typically constructed from one or more plastic films and sometimes coated with aluminum foil. That great multi-layered construction is great for providing a complete barrier to protect products, increase shelf-life, and provide durability. But surely, that’s not the best construction for sublimation; therefore; Mylar does not typically accept ink into its fibers or surface a...

Why Mylar Bags Alone Aren’t Enough for Long-Term Storage

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  Mylar bags help block the most common threats to food freshness (light, moisture and air) but they do not remove any oxygen trapped inside the bag. Therefore, while Mylar will prevent further degradation from threats coming into contact with your food, without removing any oxygen already trapped in the bag your food will degrade in quality (through oxidation) even though the bag is completely sealed. Oxidation continues, although at greatly reduced rates, long after your food is placed in a sealed Mylar bag. Over time, food stored in sealed bags will degrade, and in many instances you will have no warning until you eat the food and realize the decline in quality. For food products that contain oils or fats (e.g., grain products, cereal mixes, etc.), the presence of oxygen in the sealed bag will cause the oil/fats to degrade (i.e., develop off-flavors) which will reduce the food’s nutritional value as well. While the presence of oxygen can limit long-term storage, most people inco...

Why Amazon Restrictions Created So Much Confusion Around Mylar Bags

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  Much of the fear surrounding Mylar Bags isn’t due to any official government regulation but rather because sellers woke up one morning to discover all their products had disappeared overnight from Amazon without warning. What took place was an unexpected disruption, and disruption happens quickly. Amazon does business differently than any other marketplace. Amazon employs a large number of automated systems for scanning product listings, images, and text using keywords to identify possible violations of the site’s policies. If a product is flagged as violating an Amazon policy, then that item can be removed from the site without notice, regardless of whether or not the seller has been given a violation notice. This is really how Mylar Bags have ended up in trouble. The issue is not with the product itself, but rather how customers have come to associate Mylar Bags with a number of different markets such as cannabis and vaping. As a result of this association, sellers began to vie...

Custom Stand Up Pouches: Benefits, Uses, and Why Brands Prefer Them

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  Over the past 10 years, packaging trends have changed rapidly and the stand up pouch has gained a lot of market share. These flexible packages utilize a bottom gusset that allows the pouch to sit upright on store shelves, making it easier to display products for customers to see and notice. Industries across food, supplements, coffee, snacks, and even pet products are moving to this type of format because it provides an excellent balance of display and practicality. One of the major benefits of stand up pouches is that they save space in shipping and storage. Flexible packaging uses much less material compared to rigid containers or boxes, allowing it to be compressed more efficiently in shipment. Thus, it reduces freight charges and allows for less square footage in a warehouse. Many brands are investigating the use of custom stand up pouches to reduce packaging costs while maintaining shelf appeal. Stand up pouches also provide excellent protection of products. Most stand up po...

Can You Seal Mylar Bags with a Hair Straightener? Here’s What Actually Works

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  Sealing Mylar bags without utilizing a commercial heat sealer may sound like an easy alternative, but if you know how to use it right, it can be a valid solution. By using a normal hair flat iron, you will achieve sufficient consistency of heat to melt the internal layers of the Mylar pouch, effectively sealing it tightly enough to block out air and moisture. For small quantities of storage, home storage, and quick packaging needs, this technique tends to be very dependable. The main consideration here is how to manage that balance. Too much heat will distort the plastic, while too little will create weak areas that end up failing. On average, most people have had success using a medium heat setting and they’ve started by testing it on a spare edge first. The process takes more patience than speed; therefore, the technique is all about applying an even, constant pressure along the top edge of the bag throughout the entire sealing process. To start with, it is critical to remove a...

Why High Barrier Packaging Is Used Across Many Industries

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  In addition to being the external container for the product within, many times packaging is essential to helping keep the quality and safe use of a product as well as providing an extended shelf life. Mylar bags have become a main source of packaging for a variety of different products. Mylar bags are manufactured from a special type of film, which is a type of special polyester film. This film creates a strong barrier to air and moisture. When products are placed inside Mylar bags and sealed properly, the internal storage conditions will remain much more stable than when stored in conventional plastic. This stable environment helps protect the integrity of sensitive components contained within the product. Food manufacturers use Mylar bags to package many snack foods, powders, coffee, and dehydrated products. If the components in these products were not protected with strong barrier layers, they would lose their flavor and absorb moisture from their environment very rapidly. Myl...

How Businesses Source Wholesale Custom Mylar Packaging

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Wholesale Mylar Bag Supplier Tips If your business relies on Flexible Packaging/ Mylar Bags, establishing a reliable supplier for wholesale orders of Mylar Bags is essential for your brand. Ordering in wholesale can reduce the cost per unit as well as increase uniformity of the product’s packaging throughout several production runs. A lot of emerging companies opt to source this way because they are able to forecast their product demand consistently. The most common supplier of wholesale Mylar Bags is typically a direct manufacturing facility. By sourcing directly from the manufacturer, businesses can customize bag sizes, printing methods and materials, and cut out the “middle man” cost often added by the wholesale reseller. Additionally, sourcing directly allows for better communication throughout the design and production process. As previously mentioned, when sourcing wholesale packaging, production capabilities of the manufacturers are often considered. Manufacturers that have adva...