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Custom Mylar Pouches from TheCardboardBoxes offer airtight, moisture-resistant sealing for food, snacks, and retail products. Our pouches keep contents fresh while displaying your brand with vibrant printed designs. Available in stand-up, flat, gusseted, and shaped styles with resealable zippers and tear notches. Print your logo, product info, and brand designs in full color. Order Mylar Pouches from TheCardboardBoxes with low minimums, free design support, and fast worldwide delivery.
A mylar pouch is the broad category that encompasses the majority of foil laminate flexible packaging. Coffee bags, supplement sachets, cannabis bags, food storage pouches, and spice packets are all mylar pouches. They share the same fundamental material construction and the same core function: protecting what's inside from oxygen, moisture, and light.
Understanding mylar pouches as a category means understanding the range of options available, how to select the right specification for your product, and what customisation options are available.
The term 'mylar' originated as a DuPont brand name for polyester (PET) film and has become a generic term in packaging for any foil laminate flexible pouch. In commercial packaging, a mylar pouch typically refers to a multi-layer laminate bag that includes:
- An outer PET (polyester) film layer: printable, durable, clear or metallic
- A middle aluminium foil layer: provides the critical barrier performance
- An inner polyethylene (PE) film layer: food-safe, heat-sealable
Some variations replace the foil layer with EVOH or other barrier films for specific applications, but the classic mylar pouch has the foil middle layer.
The category includes several distinct format types:
Stand-up pouches (doypacks): have a gusseted base that allows the filled pouch to stand upright. The most common retail format. Available with zip lock or heat-seal closures, with or without hang holes.
Flat pouches (three-side seal): sealed on three sides, open at the top for filling. Flat profile; used for sachets, single-serve portions, sample packets, and flat products.
Pillow bags: similar to flat pouches but with a slight gusset that gives more volume when filled. Common in snack and nut packaging.
Gusseted side-seal bags: gussets on the sides rather than the base; used for high-volume products and trade/foodservice sizes.
Centre-seal bags: also called fin-seal; the seal runs along the back of the bag vertically, allowing the full front panel to be used for display.
The right mylar pouch specification depends on:
Your product: What does it need protection from? High oxygen sensitivity (coffee, herbs, cannabis) needs a full foil laminate. Shorter shelf life products with lower barrier requirements may be fine with a simpler PET/PE structure.
Your shelf life requirement: Longer shelf life demands better barrier performance. Calculate backwards from your target shelf life to determine the minimum barrier specification required.
Your format requirements: Does the product need to stand on shelf? Go for a stand-up. Does it need to hang on a peg? Add a hang hole and use an appropriate shape. Is it a single-serve product? A flat sachet may be the most economical choice.
Your fill process: Pre-made pouches are filled and sealed by hand or with basic filling equipment. Roll stock on a form-fill-seal (FFS) machine forms, fills, and seals in one operation at higher speeds.
Your budget: More complex structures (more layers, premium finishes, additional features) cost more. Digital printing has lower minimum orders but higher per-unit cost than flexographic for large volumes.
Mylar pouches are fully customisable across several dimensions:
Material and barrier: standard PET/Foil/PE, upgraded specifications for demanding applications, or eco-alternatives for sustainability-focused brands.
Size and format: virtually any size is achievable, from tiny 5ml sachets to multi-kilogram bulk bags.
Print: full colour digital or flexographic printing; up to 10 colours.
Finish: gloss, matte, soft-touch matte, holographic, metallic.
Closures: zip lock, heat seal, tin tie, spout/nozzle fitment, press-to-close CR zip.
Features: clear window panels, hang holes, tear notches, degassing valves, oxygen absorbers.
Mylar pouches are used across virtually every consumer and industrial product category where flexible packaging is appropriate:
- Food and beverage (coffee, tea, snacks, dried goods, protein powder)
- Pharmaceuticals and supplements (vitamins, herbal capsules, powder formulations)
- Cannabis and hemp (flower, concentrates, edibles)
- Cosmetics and personal care (sample sachets, travel sizes, professional use)
- Pet food and treats
- Agricultural (seed packets, soil amendments)
- Industrial (electronic component protection, chemical sample distribution)
Digital printing allows custom mylar pouches from as few as 100-500 units, making it viable for small producers, new product launches, and multiple SKU ranges.
Flexographic printing delivers lower per-unit costs at volumes of 3,000-5,000 units and above, suited to established brands with predictable volume.
At TheCardBoardBoxes, custom mylar pouches are available across the full range of sizes, formats, materials, and print options. Fast UK turnaround and a clear ordering process make getting your packaging right straightforward, regardless of your volume or experience level.
| Box Style | Any Style |
| Dimension | Custom sizes and shapes |
| Quantity | 250 - 500,000 boxes |
| Paper Stock | (12pt to 24pt) Cardstock, Kraft, E-Flute Corrugated, Cardboard, Bux-Board, Rigid |
| Printing | CMYK, PMS |
| Coating | Matte, Gloss |
| Finishing | Embossing, Debossing, Foil Stamping, Spot UV |
| Included Options | Die Cutting, Scoring, Gluing, Fold & Perforation |
| Proof | Electronic Proof (flat, 3D mock-up), Hardcopy Proofing (upon request) |
| Turnaround | 5 - 7 Business Days |
| Delivery | FLAT via Courier |
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A quick-drying, water-based layer that shields paper from smudges and grime while being eco-friendly.
This liquid finish cures under UV lights, giving your paper a vibrant, glossy shine.
This glossy treatment applies only to select areas, making images or text dramatically stand out.
This unique finish creates a velvety or suede-like texture under your fingertips.
A transparent ink that safeguards the page or provides subtle gloss, though it may yellow with age.
A thin plastic film bonded to paper for durability, available in shiny or non-glare finishes.
A rugged plastic barrier that stops scratches and wear from frequent handling.
This layer delivers a luxurious smooth feel and exceptional tear resistance.
Offset printing is a high-volume printing technique using metal plates and rubber blankets.
Digital printing is a method of printing directly from digital files to media.
UV printing uses UV light to instantly cure ink onto a wide variety of materials.
It is a process that transfers ink through a stenciled mesh screen onto a surface.
Flexography is a high-speed printing process using flexible plates and low-viscosity inks.
Gravure printing is a high-quality, high-speed intaglio printing method using engraved cylinders.
This method applies heat to bond glittering metallic hues like gold or silver onto paper, creating designs that truly shimmer.
This approach raises the paper from below to form a tactile image you can feel with your fingertips.
This technique indents your design into the paper, producing a striking recessed effect that brings dimension to your work.
This unique foil shifts through a vibrant spectrum of colors like a dazzling rainbow when light strikes it at specific angles.
This glossy clear varnish targets select areas of the page to highlight particular elements with eye-catching shine.
This sleek coating delivers a non-reflective, velvety texture that feels luxurious and enhances readability.
This highly reflective layer bounces back light, amplifying colors to make your print vibrant and dynamic.
Hot foil stamping is a printing method using heat to transfer foils for decoration.
Premium solid bleached sulfate, C1S coated for vibrant prints and superior food safety.
Solid bleached sulfate, double-coated for flawless printing and premium packaging appeal.
Pure uncoated unbleached kraft ensures raw, sustainable strength for authentic eco-packaging needs.
Clay-coated newsboard delivers affordable strength with smooth surface for bold branding.
Bold black kraft exudes premium elegance and robust protection for standout packaging.
100% recycled clay-coated newsboard offers eco-friendly durability and cost-effective packaging solutions.
Rustic natural brown kraft provides authentic, biodegradable strength for sustainable food packaging.
Clean white kraft combines natural strength with bright, recyclable appeal for branding.
Rugged natural kraft corrugated board delivers eco-friendly strength for reliable food transport.
Elegant oyster white corrugated board offers subtle sophistication and sturdy packaging protection.
Smooth kemi white corrugated ensures crisp prints and robust durability for premium shipping.
Bright bleached white corrugated provides pristine appearance with superior strength for branding.
Tall A-flute excels in superior cushioning and shock absorption for fragile foods.
Fine B-flute offers smooth printing surface and efficient collapse resistance for boxes.
Versatile C-flute balances strength, printability, and space efficiency for standard packaging.
Micro E-flute creates sleek, flat profiles with excellent print quality for retail.
Single face flute adds lightweight protection and flexibility for delicate food wrapping needs.
Single wall corrugated flute balances cost and cushioning for everyday food shipping demands.
Double wall flute delivers enhanced stacking strength for heavier food packaging loads.
Triple wall flute provides maximum crush resistance for industrial food transport durability.
It is a type of paperboard with a white clay-coated top side, ideal for luxury packaging.
Grey Chipboard Cardboard is a thick, sturdy material made from recycled content, ideal for luxury packaging.
This material is slim yet robust enough to maintain its form effectively for petite, lightweight boxes and resilient cards.
An excellent balanced option that offers a firm feel and reliable safeguarding for typical gift box varieties.
This dense board has a substantial heft in your grasp and ranks as the top pick for superior, long-lasting luxury packaging.
This exceptionally sturdy and inflexible material suits bigger items requiring additional reinforcement for security.
The densest and most resilient choice on offer, giving it a near-wooden sensation for the ultimate premium goods.
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