What Is Mylar

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What Is Mylar? Uses, Thickness & Printability Explained (Ultimate 2026 Guide)

Mylar bags are everywhere today  from coffee packaging to pet treats, snacks, supplements, cannabis packaging, nutraceutical pouches, and even emergency food storage. Yet despite their popularity, many brands and converters still ask:

“What exactly is Mylar, what thickness do I need, and how do I print it?”

If that sounds like you, you’re in the right place.

This guide breaks down Mylar in simple, business-friendly language while giving you the deep technical accuracy your converters, production teams, and brand managers expect.

 Let’s dive in.

What Is Mylar? (Definition for Google & AI Search)

Mylar is a brand name for biaxially-oriented polyethylene terephthalate (BoPET), a strong polyester film known for its durability, barrier protection, heat resistance, and smooth print surface.

In simpler terms?
 Mylar is the ultra-tough, food-safe, shiny (or matte) plastic film used to make most modern flexible packaging  especially resealable bags and stand-up pouches.

Why Mylar Became the Packaging Standard

Mylar is trusted across industries because it offers:

  • Exceptional oxygen and moisture barrier performance

  • High tensile strength (it doesn’t tear easily)

  • Heat-seal compatibility

  • Lightweight construction

  • Smooth, ink-friendly surface

  • Long shelf-life stability

It checks every box brands care about: product protection, branding potential, and reliable performance.

Where Is Mylar Used? 10 Major Applications

Mylar is one of the most versatile substrates on earth. You’ll find it in:

1. Custom Mylar Bags & Pouches

The #1 use case — from food to wellness products.

2. Coffee & Tea Packaging

Oxygen barrier = preserved aroma.

3. Cannabis & CBD Packaging

Child-resistant + scent-proof performance.

4. Snack & Confectionery Packaging

5. Pet Food & Treat Bags

6. Powdered Supplements & Protein Pouches

7. Long-Term Food Storage

Preppers love Mylar for a reason.

8. Electronics & Component Packaging

Anti-static protection.

9. Medical & Pharmaceutical Packaging

10. Industrial Films & Insulation

Because Mylar is exceptionally stable across temperature ranges.

Mylar Thickness Guide: 1 Mil to 7 Mil (What You REALLY Need)

If you’ve ever been confused by “Mils,” you’re not alone.

1 Mil = 0.001 inches (0.0254 mm)

Here’s a practical breakdown:

Mylar Thickness

Best For

Why It Works

1–2 Mil

Small flat pouches, inner liners

Lightweight, low-cost

3 Mil

Standard consumer packaging

Flexible, good barrier

4 Mil

Resealable food bags, coffee, snacks

Strong + protective

5 Mil

Premium foods, longer shelf life

Higher puncture resistance

6–7 Mil

Bulk food storage, industrial uses

Extreme durability

Pro Tip:
 Most modern stand-up pouches fall between 3–5 Mil, depending on branding requirements and filling conditions.

Is Mylar Good for Printing? Understanding Printability

The short answer?

Yes — Mylar is excellent for printing, especially with modern digital inkjet technology.

But print success depends on three factors:

1. Surface Treatment (Corona or Chemical)

Untreated Mylar is too smooth for ink adhesion.
 Processors treat it to increase surface energy, making ink bond tightly.

2. Ink Compatibility

Mylar works with:

  • Pigment inkjet inks (best for durability & lamination)

  • UV-curable inks (great for labels, not ideal for food contact)

  • Solvent/eco-solvent inks (depends on food safety)

  • Flexo inks (industry standard for large volumes)

  • Gravure inks (for extremely high-volume runs)

Food, beverage, and nutraceutical brands increasingly prefer water-based pigment inkjet because it offers:

  • Excellent rub resistance

  • Food-grade compliance

  • Compatibility with lamination, pouching, sealing

  • Vibrant colors

3. Heat Sensitivity

Because Mylar films can distort under extreme heat, print engines must maintain precise temperature control.

This is where high-end systems like the ArrowJet Aqua series outperform basic inkjet printers.

Best Printers for Custom Mylar Bags (Inkjet vs. Digital vs. Flexo Compared)

Marketers and converters often ask:

“What’s the best printer for Mylar bags?”

The real answer depends on your volume, SKU count, turnaround time, and food-safety requirements.

Let’s compare the top three.

Printing Method

Ideal For

Print Quality

Setup Costs

Per-Unit Cost

Speed

Food-Safe Ink Options

Best For Mylar?

Pros

Cons

Digital Inkjet (Water-Based Pigment)

Short–medium runs, high SKU variation, fast turnaround

⭐⭐⭐⭐ High

Low (no plates)

Medium

Fast

Yes (e.g., Swiss-compliant pigment inks)

Excellent

Vibrant colors, fast changeovers, perfect for customization, supports lamination

Higher cost than flexo for ultra-high volumes

Digital Toner (Electrophotographic)

Short runs, prototypes, labels

⭐⭐⭐ Very good

Low

Medium–High

Medium

Limited

Good for Labels; Limited for Mylar Films

Sharp graphics, good for small batches

Heat sensitivity can distort films; not ideal for wide-web

Flexographic Printing

Large-volume production (≥100k+)

⭐⭐⭐⭐ High

High (plates)

Low

Very fast

Yes (depending on ink sets)

Great for High Volume

Cheapest per unit at scale, durable output

Expensive plates, slow changeovers, not flexible for many SKUs

Gravure Printing

Ultra-high volume (million+ units), premium packaging

⭐⭐⭐⭐⭐ Exceptional

Very High (cylinders)

Lowest at massive volume

Extremely fast

Yes

Excellent for Massive CPG Runs

Metallics + luxury finishes, unbeatable consistency

Extremely expensive setup, long lead times

UV Inkjet

Labels, rigid packaging

⭐⭐⭐⭐ Sharp

Low

Medium

Fast

Not ideal for food-contact Mylar without barrier/overprint varnish

Good for labels; not ideal for pouches

Immediate curing, durable

Food-safety limitations, brittle feel

Solvent/Eco-Solvent Inkjet

Banners, outdoor media

⭐⭐⭐ Good

Low

Medium

Medium

Limited for food packaging

Not Recommended

Strong colors

Ink migration concerns, odor

 

Why Digital Inkjet Is Dominating Mylar Packaging in 2026

Modern inkjet systems deliver what traditional flexo and gravure simply cannot:

  • Short Runs without financial penalties

  • Micro-versioning for flavors, batches, SKUs, and regions

  • Personalization at scale from influencer drops to limited editions

  • Lightning-fast turnarounds to keep up with fast-moving markets

  • Zero plate costs, eliminating delays and cutting waste

This combination has made inkjet the preferred choice for converters focused on premium flexible packaging.

Pros of Digital Inkjet for Mylar Films

Digital inkjet offers a set of advantages uniquely suited to the challenges of printing onto Mylar, especially when paired with pigment-based, food-safe inks:

✔ Ideal for Small to Medium Production Volumes

Inkjet empowers converters to run 500 bags in the morning and 5,000 in the afternoon—without changing hardware or printing plates.

✔ Ultra-Fast Job Changeovers

Switch SKUs, flavors, languages, or artwork with a click. Inkjet workflow is built for multi-SKU environments.

✔ Zero Plates = Lower Costs for Short Runs

Every new design printed flexographically adds cost. Inkjet eliminates plates entirely, making short runs extremely profitable.

✔ Perfect for Seasonal, Promotional & Limited-Edition Packaging

Holiday editions, collaboration drops, event packaging these projects thrive with inkjet’s flexibility.

✔ High-Resolution, Photo-Realistic Print Quality

Modern inkjet heads deliver sharp text, rich blacks, vibrant colors, and photographic detail that stand out on shelves.

✔ Works Exceptionally Well With Pigment Inks

Pigment inks are the gold standard for Mylar bags because they offer:

  • Superior durability

  • Excellent rub and water resistance

  • Stability during lamination and heat sealing

  • Fade-free performance in long storage cycles

This makes inkjet an even stronger choice for food, supplements, and cannabis applications.

Best Use Cases for Digital Inkjet Mylar Printing

Digital inkjet is the top-performing solution for converters serving high-growth packaging categories:

1. Custom Mylar Bags for Supplements

Perfect for vitamin blends, protein powders, pre-workouts, nutraceuticals, and sample-size trial packs.

2. Cannabis & CBD Packaging

Mylar bags dominate this segment because of their durability, oxygen barrier, and premium feel. Inkjet allows rapid SKU changes for strains, flavors, and compliance updates.

3. Coffee Pouches

Print small-batch roasts, origin-specific blends, or seasonal drops without minimum order headaches.

4. Limited Editions & Promotional Packaging

Brand collaborations, influencers, seasonal promos, or short-term campaigns thrive with inkjet’s flexibility.

5. Prototype & Sampling Runs

Designers and brand owners can test multiple variants quickly—critical for startups and new product development.

1. The Best Digital Printer for Mylar Bags in 2026: ArrowJet Aqua 800M

If you’re looking for a printer purpose-built for flexible packaging and Mylar,… nothing beats the ArrowJet Aqua 800M.

ArrowJet Aqua 800M
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Why It Outperforms Standard Inkjet Printers

Designed specifically for flexible packaging & Mylar films
 The wide-web format, optimized tension control, and precision drop placement make it ideal for PET, MET-PET, and multilayer films.

2. Powered by ArrowJet Pigment Inks (Swiss Ordinance Compliant)
 These inks are food-safe, highly durable, and engineered to survive:

Lamination

Heat sealing

Abrasion

Long shelf-life storage

3. High-speed, production-grade output
 Perfect for converters scaling beyond entry-level devices.

4. Ideal for short-run and medium-run Mylar bag manufacturing
 Supports multiple SKUs and variable data.

2. Flexographic Printing for Mylar (Best for Mass Production)

Flexo has dominated packaging for decades.

Pros

  • Lowest cost per unit at high volumes

  • Excellent durability

  • Wide material compatibility

Cons

  • Slow changeovers

  • High plate costs

  • Not cost-effective for short runs

  • Limited agility for SKU proliferation

Best Use Case

  • Millions of identical Mylar bags with minimal artwork variation.

3. Gravure Printing for Mylar (Premium, Ultra-High Volume)

Gravure is used by global CPG giants.

Pros

  • Highest print quality

  • Extreme consistency

  • Best for metallic, luxury finishes

Cons

  • Very expensive cylinders

  • Only profitable at massive volume

  • Long lead times

What About Hybrid Printing? The Best of Both Worlds

Hybrid printing is becoming one of the fastest-growing printing methods in flexible packaging and Mylar production — and for good reason.

Instead of choosing between digital and flexo, hybrid technology allows converters to use both on the same press, unlocking benefits neither platform can deliver alone.

How Hybrid Printing Typically Works

  • Flexo handles the high-coverage, repeatable parts
     – Solid background colors
     – Flood coating
     – White ink layers
     – Varnish or primers

  • Digital handles the dynamic, changeable parts
     – Variable data
     – SKU variations
     – Seasonal editions
     – Short-run campaigns

Why This Matters for Converters

Hybrid printing significantly reduces cost while improving operational speed:

  • Flexo prints the “cheap-to-produce” static area.

  • Digital prints only the variable or SKU-specific segments.

  • No need to waste digital ink on large backgrounds.

  • No need to create a flexo plate for every SKU.

The result?
 Lower production cost, faster time to market, and far more flexibility.

ArrowJet Hybrid Pro M: The Future of Hybrid Printing for Flexible Packaging & Mylar Bags

ARROWJET AQUA 330R HYBRID PRO M
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The ArrowJet Hybrid Pro M (Bolt 330R Hybrid Pro M) is one of the most advanced hybrid platforms available today — built specifically for converters who want high speed, low cost, and digital flexibility in one compact machine.

This system combines full flexo capability with high-resolution digital inkjet printing, giving converters the power to scale Mylar bag production like never before.

Why ArrowJet Hybrid Pro M+ Is a Game-Changer

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1. True Hybrid Architecture

This is not a “digital press with a flexo station” — it’s a fully integrated hybrid press.
 You can run:

  • Flexo → Digital → Flexo

     

  • Digital → Flexo

     

  • Flexo-only

     

  • Digital-only

This adaptability allows converters to build workflows around cost, ink usage, SKU complexity, and turn-around time.

2. High-Speed Digital Engine for Variable SKUs

Powered by advanced Memjet DuraFlex® pigment inkjet technology, the Hybrid Pro M delivers:

  • 1600 dpi resolution

     

  • Industry-leading color vibrancy

     

  • Food-safe pigment ink options

     

  • Instant changeovers for new SKUs

Perfect for Mylar bag producers managing hundreds of flavors, strains, blends, or seasonal editions.

3. Flexo Units for Coatings, White, Flood Colors & Metallics

Why waste digital ink on solid backgrounds?

The Hybrid Pro M’s flexo section allows you to:

  • Lay down white ink for Mylar films

     

  • Apply varnish or OPVs

     

  • Print brand colors at extremely low cost

     

  • Add metallic or specialty effects

     

  • Apply primers inline for optimized digital adhesion

This dramatically reduces digital ink consumption while improving durability.

4. Perfect for Mylar & Flexible Packaging Films

The Hybrid Pro M is engineered for challenging substrates like:

  • PET

     

  • Metallized PET

     

  • Clear BOPP

     

  • Laminated films

     

  • Mylar used in stand-up pouches

Its advanced web handling ensures tight tension control, which is critical for thin, heat-sensitive Mylar films.

5. Full Finishing Inline (Optional)

The system can integrate:

  • Flexo coating

     

  • Cold foil

     

  • Die-cutting

     

  • Slitting

     

  • Rewinding

Meaning converters can move from blank film → finished roll → pouching line with minimal touches.

6. Lowest Cost Hybrid Production in Its Class

With flexo doing heavy lifting on ink coverage and digital handling design variations, converters can enjoy:

  • 60–80% reduction in digital ink cost

     

  • Faster job setup

     

  • Minimal waste

     

  • Massive SKU capability without added plate cost

This makes the Hybrid Pro M especially attractive for:

  • Cannabis/cultivation packaging

     

  • Nutraceutical brands

     

  • Snack and confectionery packaging

     

  • Co-packers with frequent design changes

     

  • Private-label producers

Hybrid Printing Example Workflow

Here’s how a real Mylar job might run on the ArrowJet Hybrid Pro M:

Flexo Unit #1: Lay down white ink for metallized Mylar
 Flexo Unit #2: Print spot background colors
 Digital Inkjet Section: Print all SKUs, graphics, variable data
 Flexo Unit #3: Apply gloss/matte varnish
 Inline Finishing: Slit, rewind, or die-cut

Output:
 Perfect, ready-for-lamination Mylar rolls at a fraction of the cost of digital-only production.

Who Should Invest in the ArrowJet Hybrid Pro M+?

It’s ideal for converters who:

✔ Produce Mylar bags and stand-up pouches
 ✔ Handle high SKU volumes
 ✔ Want to cut plate costs
 ✔ Need to reduce digital ink consumption
 ✔ Require food-safe printing
 ✔ Want a single machine for both long and short runs
 ✔ Want to eliminate outsourcing

If your customers constantly request new flavors, limited editions, or rapid redesigns, this system is a strategic advantage.

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