METALLIZED BARRIER FILM

Mylar

A metallized polyester (BoPET) film valued for its near-total moisture, oxygen and light barrier, and the standard choice wherever freshness and shelf life matter more than a paper-first sustainability story.

High barrier protectionHeat-sealableExtends shelf lifeLight-blocking

Get a quote →Order free samples

12–100µ

Film thickness

24 mo

Max shelf life

2.3×

Cost index (baseline)

10–14 days

Typical lead time

Overview Products Industries How it's made Pros & cons Eco level Cost Alternatives

OVERVIEW

What is Mylar?

Mylar (BoPET) is a polyester film, often vacuum-metallized with a thin aluminum layer, that creates a near-impermeable barrier to moisture, oxygen and UV light. Paper and board alone cannot match those properties.

It is typically used as a pouch, liner or laminate rather than a structural box, most often heat-sealed into stand-up pouches or flat bags for products that degrade quickly when exposed to air or light.

SPECIFICATIONS

Technical at a glance

Thickness

12, 25, 48, 100 micron

Format

Stand-up pouch, flat bag, liner laminate

Seal type

Heat-seal, zip-lock, valve

Barrier rating

Near-zero O2 / moisture transmission

Recyclability

Limited (check local programs)

Best for

Coffee, snacks, supplements, cannabis & CBD

IN PRODUCTION

Products made with Mylar

View all products →

Mylar Ziplock Bags

Reseal is the whole proposition, so the barrier has to survive daily opening.

Weed Mylar Bags

The eighth is the retail unit, and the bag is drawn around that rather than a nominal size.

Mylar Comic Bags

Archival polyester that is chemically stable, so the bag does nothing to the book over decades.

Mylar Food Storage Bags

Sized in gallons and specified in years, for long-term storage rather than shelf life.

Mylar Vacuum Seal Bags

A metallised barrier under vacuum, with the oxygen removed and its route back in closed.

Child-Resistant Mylar Bags

A barrier pouch with a zipper only adults can work, press-to-close plus a slider lock.

Stand-Up Mylar Bags

A gusseted base that opens flat, so the bag faces the customer instead of slumping.

Smell Proof Mylar Bags

The odour barrier comes from the laminate structure, which means it can be tested rather than assumed.

WHO USES IT

Industries that rely on Mylar

Coffee & Tea

Fresh-seal barrier pouches

Snack Food

Moisture & oxygen protection

Supplements & Nutraceuticals

Shelf-stable barrier packaging

Cannabis & CBD

Compliant barrier pouches

Pet Food

Shelf-stable pouches

Pharma & Health

Moisture-sensitive product protection

Specialty Food

Artisan food barrier bags

Outdoor & Survival Goods

Long shelf-life packaging

THE PROCESS

How Mylar is made

Film extrusion

Polyester resin is extruded into a thin base film.

Metallization

A thin aluminum layer is vacuum-deposited for barrier protection.

Lamination

The film is bonded to other layers for strength and printability.

Pouch forming & sealing

The laminate is cut, formed and heat-sealed into the final pouch.

Advantages

✓

Best-in-class barrier. near-total protection from moisture, oxygen and light.

✓

Extends shelf life. significantly slows product degradation.

✓

Lightweight. lower transport weight than rigid barrier alternatives.

✓

Heat-sealable. enables tamper-evident, secure closures.

✓

Blocks light-driven degradation. protects light-sensitive products.

Considerations

–

Not curbside recyclable. most municipal programs cannot process metallized film.

–

Weaker sustainability story. less aligned with paper-first eco positioning.

–

Higher relative cost. the most expensive option in the material lineup.

–

Specialized equipment needed. heat-sealing requires dedicated machinery.

SUSTAINABILITY

Eco-friendly level

Mylar trades a weaker recyclability story for shelf-life gains that reduce food waste. Mono-material recyclable variants are emerging but not yet widely available.

✓Reduces food waste via shelf life✓Lightweight (lower transport footprint)✓Some recyclable mono-material options exist

ECO RATINGLimited · 2 / 5

LowModerateExcellent

COST COMPARISON