How to measure for custom Mylar bags

Mylar bags are sized by width, height and gusset, not by volume. Here's how to choose a size that fills well, seals cleanly and looks great on the shelf.

Understand the three dimensions

• Width: side seal to side seal across the front.
• Height: top edge to bottom, including the folded gusset.
• Gusset: the depth of the bottom panel that lets a pouch stand and expand.

Account for seals and zippers

Side and top seals take roughly 3/8 in each. Zippers sit 1 to 1.5 in below the top, and you need at least 1 in of headspace between your fill and the zipper for a clean seal.

Test with your real product

1. Weigh a typical fill.
2. Pour it into a blank bag of a likely size.
3. Check it looks about 70 to 80 percent full with headspace for the zipper.
4. Stand it on a shelf and check the front panel is visible.

Density changes everything

One pound of coffee, cereal and marshmallows need very different bags. Always test, and use our size finder as a starting point.

Plan features first

Windows, valves, spouts, hang holes and tear notches affect usable space and artwork placement. Decide on them before you finalize dimensions.

Common mistakes

• Sizing by volume without testing.
• Forgetting seal and zipper areas.
• Choosing too shallow a gusset.
• Ordering too many sizes.
• Skipping a blank sample on large orders.

Need help?

Send your product and fill weight with your quote request, and we'll recommend a size for free.