- sales@apexiopackaging.com
- +1 (123) 456-2026
Our streamlined six-step process ensures your custom packaging vision becomes reality — with precision, quality, and speed.
Share your vision, dimensions, materials & quantities — we listen and plan.
Our designers craft stunning visuals that match your brand identity perfectly.
Preview your product in realistic 3D before going to print — every angle covered.
Once you're happy, approve the final proof and we prepare for production.
State-of-the-art printing & finishing in our quality-controlled factory floor.
Fast, safe worldwide shipping — your packaging arrives ready to impress.
Custom mylar bags are high-barrier foil pouches that lock out oxygen, moisture and light, so your product stays fresh, smell-proof and shelf-ready.
A flat plastic bag lets air and aroma leak straight through; a laminated mylar pouch does not. At Apexio Packaging, we manufacture custom mylar bags in the USA for coffee roasters, snack and food-storage brands, supplement lines, and cannabis and CBD retailers. With zero MOQ, free design, a free 3D mockup and free US shipping, you can order a single test pouch or a full production run and get the same food-grade, high-barrier build every time.
Get your free quote and free 3D design proof today – email sales@apexiopackaging.com or call +1 (855) 466-6990.
Mylar bags are flexible pouches made from laminated layers of PET film, aluminium foil and polyethylene that together form an airtight, high-barrier package.
Unlike a single-layer plastic bag, a mylar pouch bonds a printable polyester outer, a foil or metalised barrier core and a heat-seal inner into one thin wall measured in mils. That structure blocks oxygen, humidity and UV light, contains odour, and holds a clean heat seal, which is why mylar packaging is trusted for products that need a long shelf life. The same pouch can be printed edge to edge, fitted with a resealable zipper and cut to a stand-up shape for retail.
Any brand selling a product that spoils, stales or smells belongs in mylar – from coffee to freeze-dried meals.
Coffee and tea roasters use pouches with a valve to keep beans fresh, while snack and food-storage brands rely on the barrier for long-term freshness. Supplement and nutraceutical lines protect powders and capsules from moisture, and freeze-dried and emergency-food makers use heavy-gauge pouches for years-long storage. Cannabis and CBD retailers choose smell-proof, child-resistant pouches for compliant, discreet packaging – and often pair them with our custom CBD boxes for a complete retail set.
The right mylar bag style depends on whether the pouch needs to stand on a shelf, lie flat, hold bulk weight or reseal.
| Mylar bag style | Best for | Why it works |
|---|---|---|
| Stand-up pouch (SUP) | Coffee, snacks, supplements | Bottom gusset lets it stand for strong shelf presence |
| Flat pouch / flat bottom | Single-serve, samples, sachets | Compact, low-cost, airtight in minimal space |
| Side-gusseted bag | Bulk coffee, grains, pet food | Expands for volume while keeping a slim profile |
| Three-side-seal pouch | Lightweight snacks, flats, powders | Simple sealed pouch, efficient for small fills |
| Child-resistant pouch | Cannabis, CBD, edibles | Certified CR zipper for compliant, discreet retail |
| Spout pouch | Liquids, sauces, powders | Screw-cap spout pours and reseals cleanly |
Choose the structure first, then layer size, film gauge, print and features. Stand-up and resealable formats suit most retail brands, as in our resealable mylar bags; flat and three-side-seal pouches keep single-serve packaging efficient.
Pouches are sized by product weight, and the chart below maps common capacities to dimensions.
| Capacity | Pouch size (W x H, inches) | Common use |
|---|---|---|
| 1 g | 2 x 3 in | Sample sachets, single flower grams |
| 3.5 g (eighth) | 3 x 4.5 in | Cannabis eighths, tea samples |
| 7 g (quarter) | 3.5 x 5 in | Quarters, spice and herb packs |
| 14 g / 1 oz | 4 x 6 in | Coffee samples, gummies, edibles |
| 4 oz | 5 x 8 in | Snacks, supplements, loose-leaf tea |
| 1 lb | 6 x 9 in (gusseted) | Coffee, granola, protein powder |
| Bulk 5 lb+ | Custom | Freeze-dried and long-term food storage |
These are starting points, not limits. We cut fully custom pouch dimensions and gussets around your exact fill weight, so the product settles cleanly and the print wraps without slack. For bulk formats see our large mylar bags.
Film thickness in mils and laminate structure are both chosen for barrier and durability.
| Material / structure | Thickness | Best for |
|---|---|---|
| PET / foil / PE laminate | 3.5-5 mil | High-barrier retail pouches |
| Clear / foil (window) laminate | 3.5-4 mil | Showing product through a clear panel |
| Kraft / foil laminate | 4-5 mil | Natural look with a full barrier |
| Matte metalised film | 3-3.5 mil | Premium soft matte finish |
| Heavy-gauge PET / foil / PE | 5-7.5 mil | Freeze-dried and long-term storage |
Thicker film means a tougher, more puncture-resistant pouch and a longer storage life, while 3.5 mil suits lightweight snacks and samples. Our food-grade laminates are built for food-contact use; follow FDA food-contact guidance when packaging edibles, and we will confirm the right structure on your proof.
We print mylar bags by three methods, chosen by run size, artwork and deadline.
| Printing method | Best for | Main strength |
|---|---|---|
| Digital printing | Short runs, samples, new SKUs | No plates, fast, low-cost startup |
| Rotogravure | Large runs, photographic art | Richest detail and colour at scale |
| Flexographic | Mid-to-large repeat runs | Cost-effective for solid brand colours |
Digital keeps a single test pouch or a short seasonal batch affordable, rotogravure delivers the crispest results across big volumes, and flexo is efficient for repeat brand-colour runs. Tell us your quantity and artwork, and we recommend the better route free.
Mylar bags print in CMYK and match exact Pantone (PMS) brand colours, while RGB stays for on-screen design.
| Colour system | Use it for | Note |
|---|---|---|
| CMYK | Full-colour art, gradients, photos | Standard four-colour print |
| PMS (Pantone) | Exact logo and brand colours | Identical shade on every reprint |
| RGB | On-screen design and previews | Convert to CMYK before printing |
CMYK reproduces full-colour artwork, while Pantone (PMS) matching locks a signature colour so every reprint of your pouch stays consistent – and metallic foil films can shift colour, so we proof them carefully. RGB is screen-only, so we convert files and confirm on your proof. Our CMYK, PMS and RGB colour guide explains it in plain terms.
Finishes set how a mylar pouch feels and shines, and most brands pair one base film with one or two accents.
| Finish | Effect | Best for |
|---|---|---|
| Matte film | Soft, non-glare surface | Premium and natural brands |
| Gloss film | Bright, high-shine surface | Bold, colour-forward products |
| Soft-touch film | Velvety tactile feel | Luxury and specialty lines |
| Spot matte / spot gloss | Contrast accent on logo or art | Highlighting key graphics |
| Foil / holographic film | Metallic or rainbow shine | Eye-catching shelf impact |
| Clear window | See-through panel | Showing product colour and texture |
Matte and soft-touch films feel premium, gloss makes colour pop, and a holographic or foil surface grabs attention, as in our holographic mylar bags. A clear window pairs with any film to reveal the product inside.
Add-ons make a mylar pouch easier to use and keep the product protected after opening.
| Feature / add-on | What it does | Best for |
|---|---|---|
| Resealable zipper | Reseals for repeat freshness | Coffee, snacks, supplements |
| Child-resistant zipper | Certified CR closure | Cannabis, CBD, edibles |
| Heat-seal top | Permanent airtight seal | Single-use and long-term storage |
| Tear notch | Easy, clean opening | Snack and single-serve pouches |
| Hang hole (euro slot) | Hangs on a peg display | Retail and impulse merchandising |
| Degassing valve | Vents CO2 without letting air in | Fresh-roasted coffee |
| Clear window | Shows the product | Snacks, coffee, dried goods |
Resealable and heat-seal closures cover most needs, while a valve keeps coffee fresh and a certified child-resistant zipper supports compliant cannabis packaging. Our smell-proof laminates and high-barrier films add moisture-and-UV protection so aroma stays in and air stays out. Ready to build yours? Get a free quote and a free 3D proof now – email sales@apexiopackaging.com or call +1 (855) 466-6990.
The whole point of a mylar bag is the barrier – it keeps oxygen, moisture, light and odour on the outside.
A multilayer foil laminate blocks the three things that ruin products: oxygen that turns food rancid, humidity that clumps and spoils, and UV light that fades and degrades. The same wall contains aroma, so smell-proof pouches keep coffee, herbs and cannabis discreet in transit. Choose a higher mil and full foil for the longest freshness, or a metalised film where a lighter barrier is enough.
We produce and ship mylar packaging for local makers and national brands across the USA.
Apexio Packaging serves brands in California, Texas, Florida, New York and Washington, and ships free to every state. A Los Angeles roaster may want valve stand-up pouches, a Denver cannabis brand may need child-resistant bags, and a Texas food-storage company may order heavy-gauge bulk pouches, all with free nationwide shipping.
Ordering wholesale mylar bags stays simple, with zero MOQ, free design and free US shipping.
Order a single pouch to test a SKU, or a large run for retail and subscription programs – bulk quantities simply unlock a wholesale price break, never a minimum. Standard production runs about 5-7 business days after proof approval, with a RUSH option. Food brands often pair mylar pouches with our custom food boxes,.
Order now with zero MOQ and free US shipping – get your free quote today.
We review every mylar bag for seal strength, barrier, print and fit before it ships.
We check heat-seal integrity, zipper function, film gauge, print registration and colour accuracy, and confirm the pouch holds up to filling, stacking and shipping. Brands that switch from plain bags to printed mylar pouches typically report longer shelf life and fewer returns, because the barrier protects the product and the print lifts its perceived value.
Your product deserves packaging that protects it and sells it. Start with zero risk: no minimums, free design, a free 3D mockup and free US shipping. Send us your product, fill weight and brand, and we turn it into a printed, high-barrier mylar pouch that earns the shelf. Get your free quote now – email sales@apexiopackaging.com or call +1 (855) 466-6990.
