Custom mylar heat seal bags in high-barrier foil film — airtight, tamper-evident packaging for food, herbs & retail. USA-made, zero MOQ & free shipping. Free!










Six simple steps stand between your idea and stunning custom packaging landing at your doorstep. No guesswork, no stress — just results.
Mylar heat seal bags are high-barrier foil pouches closed with heat instead of a zipper, giving an airtight, tamper-evident seal that blocks moisture, oxygen and light.
When a product needs to stay sealed until the customer opens it, a heat seal beats a zipper. At Apexio Packaging, we make custom mylar heat seal bags in the USA for food brands, coffee roasters, herbal-product makers and retail packagers. With zero MOQ, free design, a free 3D mockup and free US shipping, you can order one test pouch or a full run in the same high-barrier film.
Get your free quote and free 3D design proof today – email sales@apexiopackaging.com.
Mylar heat seal bags pair an airtight, tamper-evident closure with a strong barrier and retail-ready branding.
A heat seal fuses the pouch shut across the whole top, so there is no zipper gap and the pack stays airtight until it is cut or torn open. The multilayer foil wall slows moisture and oxygen to protect freshness, and the full print area carries a professional retail look. Under the print sits a PET, foil and PE laminate that carries the barrier, not paperboard.
These pouches suit any product that ships sealed and needs proof it was not opened first.
Coffee roasters seal single-origin lots, snack and spice brands lock in aroma, and herbal and wellness sellers want a tamper-evident pack. Many pair a heat seal with a tear notch for easy opening, and brands wanting a printed retail look start from our custom printed mylar bags. Zero MOQ lets a startup launch one SKU at a time.
Sizes are matched to your fill weight, and the chart shows the most requested capacities for heat-sealed packs.
| Capacity | Pouch size (W x H, inches) | Common use |
|---|---|---|
| 1 g | 2 x 3 in | Spice and sample sachets |
| 7 g | 3 x 4.5 in | Single-serve snacks and herbs |
| 1 oz | 4 x 6 in | Coffee, tea and small dry packs |
| 3.5 oz | 4.5 x 7 in | Standard retail sealed bags |
| 1 lb | 6 x 9 in (gusseted) | Bulk coffee and dry goods |
These are starting points. We cut fully custom dimensions and gussets, and flat, stand-up and gusseted formats seal cleanly. If you prefer a reclosable option instead, see our resealable mylar bags.
Mylar heat seal bags are specified by mil thickness and laminate, both chosen for barrier and seal strength.
| Material / structure | Thickness | Best for |
|---|---|---|
| PET / foil / PE laminate | 3.5-5 mil | High-barrier sealed packaging |
| White PET / foil / PE | 3.5-5 mil | Bright print with product panel |
| Kraft / foil / PE | 4-5 mil | Natural, earthy retail look |
| Clear / foil (window) | 3.5-4 mil | Showing the product inside |
The inner PE layer is what melts and fuses to form the airtight seal, while the aluminium foil core delivers the moisture and oxygen barrier and a higher mil (or micron) resists punctures. Our food-grade laminates are built for food-contact use; see FDA food-contact guidance when packaging edible products.
We print these pouches 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 and affordable |
| Rotogravure | Large runs, photographic art | Richest detail and color at scale |
| Flexographic | Mid-to-large repeat runs | Cost-effective for solid brand colors |
Digital keeps a first run affordable, rotogravure delivers photographic detail at scale, and flexo suits repeat brand-color runs. There is room for your logo, product name and an ingredient panel.
We print in full CMYK for photos and artwork and match exact Pantone (PMS) colors for logos, then confirm every color on your digital proof. Our color guide explains CMYK, PMS and RGB in plain terms.
Finishes decide whether your sealed pouch reads natural and matte or bright and glossy.
| Finish | Effect | Best for |
|---|---|---|
| Matte film | Soft, non-glare surface | Natural, premium products |
| Gloss film | Bright, high-shine surface | Bold retail impact |
| Soft-touch film | Velvety tactile feel | Premium retail lines |
| Spot gloss on matte | Shine accent on a matte base | Logos and key graphics |
| Metallic or holographic foil | Reflective shine | Standout branding |
Matte with a spot-gloss logo is the most popular premium look, while gloss and foil add shelf drama. A clear window shows the product without breaking the seal.
Add-ons make a heat-sealed pouch easier to open and fit specific products, without giving up the airtight seal.
| Feature / add-on | What it does | Best for |
|---|---|---|
| Heat-seal top | Permanent airtight, tamper-evident seal | Sealed retail and long storage |
| Tear notch | Easy, clean opening on a sealed pouch | Single-serve packs |
| Hang hole | Displays on retail pegs | Small sealed packs |
| Degassing valve | Vents coffee CO2 without letting air in | Fresh-roasted coffee |
| Child-resistant option | Restricted-access closure | Products needing CR packaging |
A tear notch keeps a sealed pouch easy to open, a valve suits fresh coffee, and a child-resistant option is available where restricted access is required – closures we also build into our mylar weed bags. Ready to build yours? Get a free quote and 3D proof – email sales@apexiopackaging.com.
A mylar heat seal bag stays airtight and contains aroma from the line to the shelf.
Because the seal runs across the whole top, there is no zipper gap for air or odor to escape, so smell-proof packs stay discreet and the foil laminate slows the moisture and oxygen that stale product. Match a higher mil and full foil layer for the strongest barrier, and keep smell-proof and freshness claims tied to your film spec and test data.
There is no minimum order, and wholesale pricing improves as volume grows.
Test a single heat seal pouch first, then scale to a larger run for lower per-unit pricing – never a forced minimum. Standard production runs about 8-12 business days after proof approval, with a RUSH lane. Retail sellers often pair these pouches with our custom food boxes.
Order now with zero MOQ and free US shipping – get your free quote today.
We review every mylar heat seal bag for seal, barrier, print and fit before it ships.
We test heat-seal strength across the full top, check film gauge and print registration, and confirm the laminate is intact with no pinholes. Brands that switch to printed high-barrier sealed pouches report a more professional, tamper-evident presence [illustrative].
Helpful reading: our guide to how to seal mylar bags.
Give your product an airtight, tamper-evident pouch that protects and sells it. Start with zero risk: no minimums, free design and free US shipping. Send us your product and fill weight, and we turn it into a printed mylar heat seal bag – email sales@apexiopackaging.com.
| Box Style | Mylar Heat Seal Bags |
| Dimension (L + W + H) | All Custom Sizes & Shapes |
| Quantities | No Minimum Order Required |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Printing | No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors |
| Finishing | Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling |
| Included Options | Die Cutting, Gluing, Scored, Perforation |
| Additional Options | Eco-Friendly, Recycled Boxes, Biodegradable |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 8-12 Business Days, RUSH |
| Shipping | FLAT |

14pt cardstock is a lightweight yet sturdy paperboard commonly used for product packaging, postcards, and promotional prints that require flexibility with reliable durability.

16pt cardstock offers a thicker, more durable structure than standard paperboard, making it ideal for business cards, premium packaging, and high-quality printed materials.

18pt cardstock provides enhanced rigidity and strength, perfect for luxury packaging boxes, product tags, and marketing materials requiring a premium and durable feel.

24pt cardstock is an ultra-thick paperboard delivering maximum strength and premium quality, commonly used for rigid packaging, luxury boxes, and high-end product presentation.

Thin yet durable E-flute corrugated cardboard (1/16") provides a smooth printing surface and reliable protection, making it ideal for lightweight retail and ecommerce packaging boxes.

B-flute corrugated board (1/8") offers excellent strength and cushioning, perfect for shipping boxes, product displays, inserts, and durable custom packaging solutions.

Strong white kraft corrugated stock with a clean printing surface enhances branding while delivering reliable protection for custom printed shipping and retail packaging boxes.

Eco-friendly brown kraft corrugated material provides excellent durability and strength, making it ideal for shipping boxes, inserts, sleeves, and sustainable packaging solutions.

Copper foil stamping adds a warm metallic shine that enhances logos and designs, giving packaging and printed materials a premium and sophisticated appearance.

Gold foil creates a luxurious metallic finish that highlights branding elements and adds an elegant touch to premium product packaging and marketing materials.

Silver foil stamping delivers a sleek metallic effect that enhances packaging aesthetics and makes logos or design elements stand out.

Holographic foil produces vibrant rainbow reflections that create eye-catching packaging designs and add a modern, futuristic look to products.

Debossing presses the design into the material surface, creating a subtle recessed effect that adds texture, depth, and elegance to packaging.

Embossing raises design elements above the surface, creating a bold 3D effect that enhances brand visibility and packaging appeal.

Fluorescent inks produce brighter, glowing colors that instantly grab attention and make packaging designs stand out on shelves.

Spot UV applies a glossy coating to selected design areas, creating contrast on matte surfaces and highlighting logos or graphics.

Matte lamination provides a smooth, non-glossy finish that enhances durability while giving packaging a sophisticated and elegant look.

Gloss lamination adds a shiny protective layer that boosts color vibrancy and makes packaging designs appear bright and eye-catching.

Velvet lamination creates a soft-touch texture that feels luxurious and enhances the premium look of high-end packaging.

Uncoated paperboard offers a natural, eco-friendly texture ideal for sustainable packaging and brands seeking an organic appearance.