Thanks to modern technologies, product presentation is no longer boring, as brands have moved beyond the era of plain cardboard boxes. Die cut mylar bags are one of the innovative packaging solutions that effectively portray a brand image in the market. Since these bags are made from BOPET film, sustainable options such as Kraft paper are also available for brands that want to attract eco-conscious consumers. The ease of use, along with an extended shelf life of approximately 20-30 years for dry goods, and a glossy surface positively impact consumer perception.

Whether you are running a food brand, a cosmetics line, or seeking a safe packaging option for your herbal products, consider using these bags from us to enjoy multiple advantages at once. You can incorporate die-cut windows to quickly catch customers’ attention.

Significance Of Die Cutting In Mylar Bags 

Not one kind of packaging can fit different products – a rule of packaging no one can deny. The crucial role of die cutting is appreciated here because it allows for unique sizes, shapes, and designs to meet each product’s requirements. Custom shaped mylar bags provide a better fit for the presentation your brand desires. The following is a more detailed overview of the importance of die cutting in custom mylar bags:

• Customisation and product fit

• Various shape options beyond rectangular and square bags.
• Tailored sizes perfectly suited to product dimensions.
• Branded designs with logos and unique patterns to promote the brand.

• Enhanced protection and preservation

• Strong protection against moisture, air, and light that can affect preserved food quality.
• Ziplocks and tear notches at the top offer resealability that extends the shelf life of products.

• Functional packaging solutions

• Custom child-resistant closures, like zip locks and adhesive strips, are possible with die cutting.
• Hang holes and handles offer functionality and ease of use.

• Cost effectiveness and efficiency

• An economical packaging option for producing large quantities of custom shape die cut mylar bags.
• Reduced materials waste contributes to saving packaging costs.

Why Mylar?

The first mylar was created by DuPont, a brand that develops technology-based materials. They were first developed in 1952, and after that, keeping in view their functionality, they have gained enormous popularity in the packaging industry. The polyester film, which is the core of customised die cut mylar bags, provides excellent tensile strength and durability.

The Manufacturing Behind The Bag

The manufacturing of mylar bags involves various steps that offer unique customisation options. From selecting the desired thicknesses of the base material to the required closure method, you can optimise the production system according to product type. The following are the main steps that contribute to the final product quality and uniqueness.

Material Selection

Mylar materials are the primary elements that distinguish them from other packaging options. The most commonly used material for personalised die cut mylar bags

is PET, though additional metallised films or sealant layers can be applied to enhance their barrier properties and appearance.

PET: Polyethene Terephthalate comes from the family of polyesters. This material is stretched into two perpendicular directions, which is a process called biaxial orientation.

Metalised coating: A thin layer of aluminium is applied on PET with a vacuum deposition method. In this process, the metal or aluminium is evaporated and then compressed onto the Mylar surface.

Sealant layers: A durable layer of BOPET is applied on the surface of aluminium that provides an exceptional barrier against moisture, heat and air. Sealant layers enhance the transparency and reflectivity of Mylar bags.

Lamination

Lamination on mylar packaging enhances their visual appeal and bonds all the layers of base materials together. We usually use the heat and pressure technique to apply your desired lamination techniques on custom die cut mylar bags with logo. The following are some types of lamination that increase the bag’s durability:

• Clear lamination
• Gloss lamination
• Matte lamination
• Soft touch lamination
• Holographic lamination

Printing And Branding

Marketing your brand by selecting the attractive design elements with brand-related graphics can result in high consumer engagement. Printing gives a unique competitive advantage to make your brand unique from all the others in the industry. From foil-stamped inks to holographic mylar bags, you can opt for several alluring options to make a statement in the market. The following are the techniques we use:

• Offset printing
• Digital printing
• Screen printing
• Flexographic printing
• Gravure printing

Custom printed die cut mylar bags create a professional brand image and help people recognise you effectively, even if you are selling the smallest thing. We use updated colour systems, such as CMYK, PMS and RGB, which help you get the clear branding elements listed below:

• Company logo
• Unique selling points
• Bold texts
• QR codes
• Descriptive texts
• Minimalist designs

Die Cutting

The main ingredient behind the unique shapes of mylar is precise die-cutting techniques. We provide high-quality techniques with no hidden costs for custom irregular shape die cut mylar bags. No matter how complex your design is, we will make sure you deliver the well-finished and refined shapes of mylar for your brand. The process we use produces intricate designs and practical features on your custom-shaped mylar bags to put the consumers at ease:

Design Blueprint: A visual guide for creating the bag, usually called a bag template. The die line highlights all elements of mylar before it reaches the die cutting method, such as the closure system, windows and main body shape.

Die Crafting: A sharp metal blade is prepared according to the selected design of the bags. Here, the custom dies are created to match the design.

Precision Cutting: The mylar film is placed in the die-cutting machine, which makes precise cuts according to the design being created. It results in uniform edges and accurate cuts, which helps in creating leakage-proof bags.

Feature Integration: After the main shape of mylar is created, special requested features from clients, such as window patches and tear notches, are added.

Quality Control: Finally, the quality checks are conducted to look for any flaws that may occur during die cutting. If all the elements are accurate, then mylar is shifted to the next step of production.

Whether you need zipper closure or teat notches, our following techniques offer precision and accurate die cutting. Furthermore, there are no size limitations as you can select any size with a unique shape, just according to your brand requirements. The following are the techniques applied at our place:

• Manual die cutting
• Automated die cutting
• Rotary die cutting
• Laser die cutting
• Flatbed die cutting

Pouch Formation And Sealing

In the final step, the bag is given the desired structure by using adhesives or heat sealers. Whether you have requested flat bottom, side suggestions or spout pouches, we make sure to seal your box perfectly.

Common Uses Across Industries

Custom die cutting of customised mylars allows brands to utilise them in different industry applications. We, as a die cut mylar bags wholesale manufacturer, provide versatile and durable bags that can cater to your various product needs.

Eco-Friendly Mylar Packaging Option 

With the growing concerns of eco-conscious consumers, every brand looks for eco-friendly packaging choices to maintain its sales. We provide eco-friendly custom die cut mylar bags in UK made from Kraft and PLA materials. These bags are treated with non-toxic printing inks and coatings to further enhance their biodegradability. The following are the options if you have the same concerns:

Kraft mylar bags: Made from kraft paper that provides durability and rustic appearance. Commonly used for pet foods, herbs and dry fruit packaging.

Biodegradable mylar bags: Bioplastics or plant-based polymers are used that help reduce plastic waste by breaking down naturally into the environment.

Why They’re The Brand’s Best Friend

What does a brand need from its retail packaging? Protection, presentation and promotion. Customised and durable mylars will help you achieve all the Ps, along with limitless customisation options to resonate with brand identity. The following elements explain how they build your brand:

• Unique shape = Brand recall
• Professional look = Trust
• Strong barrier = Product integrity
• Custom printing = Storytelling

Stand Out With Custom Boxes Market

Want protective mylar packaging in special product-related shapes? Custom Boxes Market offers several customisation options so your bag must work out for your product and brand success. From free design assistance to no hidden costs, we make sure that our customers remain satisfied by collaborating with us. A dedicated customer service team is available to listen to all your concerns and provide a possible solution according to your brand and budget.

Order our ready-to-use custom die cut mylar bags no minimum of 1000. If you want to enjoy amazing discounts with free physical shapes, then choose large quantities!