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Printing on Mylar bags is done using professional methods like digital, flexographic, or rotogravure printing, where ink is applied to the outer polyester layer and often reverse-printed before lamination for durability, safety, and high quality results.
While printing on Mylar bags is essentially adding ink to plastic, this is done through a controlled manufacturing process. Not only does this determine the shelf life and durability of the bag but it also affects compliance and how the finished product performs in real world applications.
If you package food, supplements, cosmetics, electronics, coffee, or any of the other consumer goods in Mylar bags then understanding how Mylar bags are printed will help you to make better quality decisions and avoid costly mistakes.
The following guide describes in detail how printing on Mylar bags works, what methods can be utilised, and why the printing process typically is more important to brands than they know.
What Are Printed Mylar Bags Made Of?
If you’re going to have any success at all with printed Mylar bags, it helps if you know how those bags are constructed.
“Mylar” is a DuPont created polyester film that refers to the general usage of this polyester film in food packaging. In actuality though, packaging made from Mylar typically consists of a laminate, or multi-layer, packaging structure that is made of:
- Outer polyester film (strength & print clarity)
- Aluminum foil layer (oxygen/moisture barrier)
- Food-grade plastic film, i.e. Polyethylene, which allows for heat sealing to the bag as well as making contact with your product.
The printing process is performed on the outer polyester film, not on the food contact film. That is a very important safety issue, as well as durability, and adheres to all regulations.
The Main Ways Mylar Bags are Printed
There is no single way to print on Mylar bags. The right method depends on order size, design complexity, and how the printed mylar bag will be used.
- Digital Mylar Bag Printing
Digital printing is best for short runs and fast turnarounds.
How it works:
- Artwork is printed directly onto the Mylar film using digital presses
- No plates or cylinders are required
- Each print can be changed without added setup cost
Best for:
- Low minimum orders
- Test runs and limited editions
- Brands that update designs often
Tradeoffs:
- Slightly higher cost per bag at scale
- Fewer specialty finishes compared to other methods
- Flexographic Mylar Bag Printing
Flexographic printing uses flexible plates and is common for mid to large production runs.
How it works:
- Ink is transferred from plates to the Mylar film
- Each color uses its own plate
- Printing happens at high speed on rolls of film
Best for:
- Consistent high volume orders
- Simple designs with fewer colors
- Faster production once set up
Tradeoffs:
- Plate costs upfront
- Less detail than gravure for complex artwork
- Rotogravure Mylar Bag Printing
Rotogravure is the highest quality printing method used in premium flexible packaging.
How it works:
- Designs are engraved into metal cylinders
- Ink fills the engraved cells and transfers to film
- Produces extremely sharp and consistent results
Best for:
- Large scale production
- Photorealistic designs
- Metallic, gradient, and high detail artwork
Tradeoffs:
- High setup cost
- Not practical for small orders
Why Reverse Printing Matters
High-quality Mylar bags generally utilize reverse printing to create their graphics.
Rather than printing directly onto the exterior surface of the bag, the graphic design is printed onto the interior side of the outer film layer of the bag, and then laminated behind the exterior (outer) film. The purpose of this is to protect the graphics from:
– Scratching or scuffing
– Moisture and/or oil
– Fading during transportation or other handling
Reverse printing is one of the major differences between professional Mylar bags and low cost/non-high quality stock bags.
Brands that want more control over finishes, print placement, and material layers usually explore printed Mylar bag options once they understand how the printing process works.
Inks Used for Printing on Mylar Bags
Not all inks are safe or will work well when printed onto Mylar.
Professional manufacturers will utilize the following inks:
- Low migration inks that are safe for food and/or consumer products.
- Water-based or solvent-based inks that are designed for applying onto flexible films.
- Inks that have been tested for adhesion, scratching and/or resistance to heat seal.
Choosing an inappropriate ink for printing onto Mylar can cause future problems such as peeling, cracking, or contaminating your product.
Can You Print on Mylar Bags Yourself?
This is viable, theoretically speaking. At the present time, however, professional printing methods cannot give satisfactory results, as follows:
Home usage of methods such as sticker application, heat transfer or desktop printer use are :
– They do not adhere well to Mylar
– Will not withstand heat sealing
– Scratch and peel easily, and
– Will not be uniform across display shelves.
If your packaging must provide protection to the product inside, be able to withstand shipping and display branding, only professional printing will be an appropriate method of printing.
Design Considerations Before Printing Mylar Bags
Prior to getting a printed piece of artwork done, there are many technical things that must be set up correctly, such as:
- Bleed areas for sealing and trimming
- Safe areas so that zippers and gussets do not distort
- Proper color profiles (i.e. CMYK and/or Spot Colors)
- Finish selection (e.g. matte, gloss, soft touch, etc.)
- Compliance space (ie. space required for nutritional panels and/or warning labels)
Failure to follow any of these steps may result in reprinting or unusable inventory.
Why Printing Quality Impacts Shelf Conversion
Packaging makes an immediate impression on consumers. High-quality printing, vibrant colors, and smooth surfaces can convey brand quality prior to any actual contact with the product being packaged.
However, printed Mylar bags will not only enhance the quality of your brand and its product(s), this will also enhance the perceived value of your product(s), reduce damage and return, and position them well against competing products in high-traffic retail display areas.
In summary, serious brands consider printing to be part of product development rather than an afterthought.
Conclusion
Printing on Mylar bags is a complex process involving multiple disciplines, including materials science, ink chemistry, and design accuracy. The printing method you choose has an effect on both the visual appearance of the bag as well as the long-term performance of the bag.
If you want your packaging to perform correctly, meet compliance requirements, and actually “convert at the shelf”, you need to understand how Mylar bags are printed.
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