How to print custom mylar bags
Custom-printed Mylar bags can turn plain packaging into a branded part of the product experience. They can display a logo, product information, colours, instructions, and other graphics while still providing the barrier properties packaging needs.
However, printing on this type of packaging is different from printing on ordinary paper. The material, artwork, ink system, printing method, and bag construction must all work together.
If you’re planning custom packaging, understanding the process can help you prepare artwork correctly and avoid production issues.
What Do You Need to Print Custom Mylar Bags?
Before production begins, several decisions need to be made:
- Bag size and shape
- Material and construction
- Printing method
- Ink system
- Artwork and colour requirements
- Quantity
- Finishing and sealing requirements
These specifications can affect both the finished packaging’s appearance and the available production options.
Choose the Right Bag Size and Shape
Start by determining how much product the pouch needs to hold and how it will be stored, displayed, or transported.
Flat pouches can work well for smaller products, while gusseted designs provide additional capacity. Stand-up pouches can also be useful when the package needs to sit upright on a shelf.
Consider more than just the product’s dimensions. Leave enough space for sealing and decide where you want the logo, product name, required information, and other graphics to appear.
Your packaging supplier or printer can help confirm the printable area and final dimensions before production.
Select a Suitable Printing Method
The printing method depends on the packaging material, quantity, artwork, and production requirements.
Digital Printing
Digital printing suits shorter runs, variable designs, and projects where you want to avoid creating traditional printing plates.
It can also make it easier to produce different designs within the same order, depending on the printer and production setup.
Flexographic Printing
Flexographic printing is commonly used for packaging production and can be practical for larger quantities. It uses printing plates and is designed for efficient repeat production.
The initial setup can make this approach less practical for very small orders, but larger runs may benefit from its production efficiency.
Rotogravure Printing
Rotogravure is another commercial packaging process used for high-volume production and detailed graphics. It involves engraved cylinders and typically requires more extensive setup.
The right method depends on quantity, design requirements, and the supplier’s equipment.
Prepare Your Artwork
Your artwork needs to match the final packaging specifications before production begins.
Check the following with your printer:
- Finished bag dimensions
- Printable area
- Bleed and safe areas
- File format
- Colour requirements
- Resolution
- Placement of logos and text
- Areas needed for seals, zippers, or other features
Avoid placing important text or graphics too close to edges, seals, or folds.
If your design includes photographs, gradients, fine text, or multiple colours, discuss these elements with the printer before finalising the file. They may have specific requirements based on the production method.
Check Colour and Print Requirements
Colours can look different on packaging materials than on a computer screen.
Your printer may recommend a specific colour mode, profile, or proofing process depending on the equipment being used. Pay special attention to brand colours if colour consistency matters across different packaging runs.
A proof or sample can help you review the artwork before committing to a larger production run.
Test the Packaging Before Full Production
A test run or physical sample can reveal issues that are difficult to spot on screen.
Check:
- Graphic placement
- Colour appearance
- Text readability
- Alignment
- Sealing areas
- Overall finish
- How the design looks on the actual pouch
This step is especially useful when the packaging has folds, gussets, curved areas, or other features that affect how the artwork appears once assembled.
Review the Finished Sample
Before approving a large order, inspect the sample carefully.
Make sure the design matches the approved artwork, and that important information remains clear. If the packaging will be heat sealed or handled during filling, check that the printed areas do not interfere with those processes.
If changes are needed, make them before full production, not after the entire batch has been manufactured.
Print the Final Quantity
Once the artwork, material, colours, and sample have been approved, the supplier can proceed with the production run.
For larger orders, keeping the approved specifications consistent helps reduce variations between batches. Your printer may also retain the production details for future orders, making repeat packaging easier to reproduce.
Can You Print on Mylar Bags at Home?
Not usually with a standard desktop printer.
Packaging films and finished pouches require printing equipment designed for the material and production process. The surface may also require specific inks or treatments for proper adhesion.
If you need a small number of custom packages, ask a packaging or commercial printing provider about available short-run options rather than attempting to feed finished pouches through an ordinary office printer.
What Should You Ask a Printer Before Ordering?
Before placing an order, give the printer as much project information as possible.
Ask about:
- Available bag sizes and structures
- Minimum order quantities
- Printing methods
- Colour options
- Artwork specifications
- Proofing
- Finishing
- Production time
- Repeat-order requirements
Also explain how the packaging will be used. A pouch intended for retail display may have different requirements from one designed primarily for storage or shipping.
How Much Does Custom Mylar Bag Printing Cost?
There is no single price because several factors affect the total cost.
These can include the bag size, material, quantity, number of colours, printing method, finishing, artwork requirements, and setup costs.
Larger quantities may reduce the cost per bag, while complex designs or specialised construction can increase production costs. Requesting a quote based on your exact specifications will give you a more useful estimate than using a general per-bag price.
Conclusion
Printing custom Mylar bags involves more than simply putting a design onto a pouch. The bag structure, printing method, artwork, colours, and production requirements must all work together.
If you would rather leave the production to a professional, Triboro Printing offers packaging and label printing services in NYC. The team can help you discuss your packaging requirements, artwork, quantity, and printing specifications before production.
