What is a Mylar Bag?

Mylar is a brand name for BoPET, a biaxially oriented polyester film. A “Mylar bag” is normally a metallized or foil-laminated polyester pouch, used where a high oxygen and moisture barrier is needed — long-term food storage, coffee, pet food and pharmaceuticals.

Why Mylar Comes Up So Often

When people talk about long-term food storage or premium product packaging, the term Mylar bag almost always comes up. But what exactly is it—and why is it so popular across industries from food to pharmaceuticals?

At Hawk Packaging, we help brands design and manufacture Mylar packaging that not only preserves freshness but also enhances visual appeal and shelf performance. Whether you’re sealing coffee beans, dog treats, or nutritional powders, understanding Mylar film is key to choosing the right packaging structure.

What is a Mylar Bag?

“Mylar” is a registered trademark of DuPont Teijin Films, still live and actively used, for a special type of polyester film known as biaxially oriented polyethylene terephthalate (BoPET). In packaging, it’s prized for its exceptional barrier properties—protecting against oxygen, moisture, and light.

A typical Mylar bag is made from multiple laminated layers:

• Polyester (PET): for strength and printability
• Aluminum foil: for light and oxygen barrier
• Polyethylene (PE): for heat sealing and flexibility

This layered structure makes Mylar one of the most durable and protective packaging materials available today.

Why Mylar Bags Are So Effective

1. Outstanding Barrier Performance

Mylar’s biggest advantage is its barrier capability. It blocks air and moisture far better than standard plastic films, helping keep food, supplements, and pet products fresh for months—or even years.

2. Long Shelf Life

Because of its low permeability, Mylar helps maintain product integrity over long storage periods. It’s commonly used for long-term food storage, coffee, and powdered goods that require protection from humidity and UV exposure.

3. Heat Sealable & Printable

Mylar is easy to seal, whether through heat sealing or zip closures, and supports vibrant, high-definition printing—perfect for custom branding and retail display.

Common Uses of Mylar Bags

Mylar packaging is used in almost every consumer category. Some of the most popular applications include:

• Pet Treats: Brands use Mylar for custom dog treat packaging because it protects against moisture and odor loss while giving products a premium look.
• Health Supplements: Custom supplement packaging often relies on Mylar films for tamper resistance and oxygen protection.
• Food & Snacks: Visit our snack packaging page to see how Mylar pouches enhance barrier performance for nuts, jerky, chips, and more.

How Mylar Compares to Other Packaging Materials

While Mylar isn’t always the cheapest option, its combination of durability, print clarity, and barrier performance make it the industry’s preferred choice for high-value products.

Sustainability & Modern Mylar Options

Sustainability has come a long way in Mylar packaging. New versions incorporate post-consumer recycled plastic (PCR) or mono-material structures that improve recyclability without compromising barrier performance.

At Hawk Packaging, we offer recyclable and PCR-enhanced Mylar laminates that align with retailer and state sustainability requirements—ideal for brands looking to modernize their packaging responsibly.

Hawk Packaging: Experts in Custom Mylar Solutions

We help brands create custom Mylar bags that combine beauty, protection, and functionality. Our engineering team fine-tunes thickness, finish, and laminate combinations to meet product-specific needs—whether it’s moisture control for coffee or odor lock-in for pet treats.

We proudly serve businesses nationwide, including those in New Mexico and Nevada, delivering fast turnaround times and premium results on every order.

Conclusion: Mylar Bags That Work as Hard as Your Product

So, what is a Mylar bag? It’s more than just a pouch—it’s a precision-engineered barrier that protects your product, enhances your brand, and extends shelf life. At Hawk Packaging, we design Mylar bags that do it all: keep products fresh, meet sustainability standards, and look incredible on the shelf. From design to production, our team ensures your packaging performs just as well as the product inside.

For detailed information on food-contact materials and their safe use in packaging, refer to the FDA’s Food Ingredients & Packaging-Materials resource.

Frequently Asked Questions

Is Mylar the same as BoPET?
Mylar is a registered trademark of DuPont Teijin Films for its BoPET polyester film, so the film itself is BoPET. A bag sold as a Mylar bag is usually a laminate in which BoPET is only the outer layer, with foil or metallizing providing the barrier.

What mil thickness Mylar bag do I need?
Thicker film resists punctures better but does not automatically mean a better barrier, which comes from the metallizing or foil layer. Tell your supplier the product, the fill weight and the shelf life you need rather than specifying a thickness first.

Are Mylar bags recyclable?
A foil laminate generally is not, because the layers cannot be separated. Metallized and mono-material alternatives can sometimes go to store drop-off, though they trade away some barrier performance.

What is the minimum order for custom printed Mylar bags?
Ours is 5,000 bags per design, with pricing improving at 10,000 and 25,000. There are no plate fees, and shipping is included in the quoted price.