How To Choose the Right Thickness for Your Mylar Bags Depending on Your Product

When looking for the right kind of bag for your product, there are multiple details to consider. It’s not “just a bag” but, instead, the gateway of your product to the people. Mylar® is the trade name of, a metalized, protective layer of a package that includes, polyethylene terephthalate (PET). Dupont coined the term Mylar® as the trademarked name for this plastic when they developed it.

How Is Mylar® Bag Thickness Measured?

Mylar® has several layers of laminated plastic that act as an excellent oxygen barrier, so your product is stored in the best possible condition, which is why many food and beverage companies love using it for their go-to flexible packaging

Sealant thickness is dependent on your packaging size. For small dimensions, there’s 1.5-2.5 mil; in large, there’s 4.5- 6.5 mil. If you’re looking for long-term food storage, we suggest a thicker bag because thicker bags provide better insulation from outside elements. Mylar® has relatively the same barrier property no matter what thickness sealant film it is laminated to.

Mylar® Bag Thickness for Protection and Ease of Use

Does Mylar® thickness matter? Of course, it does. When using mylar®, it’s essential to remember thickness is only a part of the solution; there’s also the aluminum metallization used for bag production. 

Mylar® bags use different materials based on advantages. Once the material has been decided, they’re laminated together to create a sturdy pouch that’s simple to use – usually a PET/ METPET/ PE mix. Many brands choose METPET to act as a barrier against the sun’s harmful rays. 

But aluminum is not heat-sealable, so it needs to be laminated with other materials like PE. Thinner bags are more susceptible to puncture damage. All MEPET specs have similar opaqueness/ UV light blocking ability

Choosing a Thickness Based Off of Food Type & Length

Opaque Mylar® bags can protect stored food for a very long time, but thickness of the material’s specs doesn’t affect shelf life in a major way

1-quart or smaller bags of 4 mil are great snack options for travel-size bags. 4 mil gallon bags are excellent for long-term storage for foods like flour, sugar, or salt. The 5.5mil bag is the most popular, though, and they’re perfect for food like pasta, granola, or beef jerky. Consider 4 mil to be the base level of thickness you’re looking for when choosing a bag.

The Right Mylar® Bag Thickness for Different Types of Food

Thicker PE layer will give better seal strength. If you’re looking for something to protect your ground coffee, a 4 mil bag is a good starting point. If your beans are whole, 5 mil might make more sense. 

For something like brown sugar, a 4 mil is one of the easiest ways to ensure safety and durability. We always suggest starting at 4 mils no matter what when it comes to long-term usage. 

Let’s talk if you’re considering jumping to mylar® for your company’s coffee, frozen foods, or granola. We’re here to help you execute your vision, one bag at a time.