Printing custom Mylar bags should not be seen just as part of the production process, but rather as a collaborative effort between chemistry, engineering, and brand psychology to create a finished product. In addition to holding retail product; finished printed Mylar bags also perform a number of other functions including protection of product aroma, blocking of light, signalling quality of the contents, and subtly influencing consumer purchasing decisions within two seconds. The focus at Brandmydispo when printing Mylar bags is on craftsmanship rather than checklists. Each layer, type of ink, and finish used is predetermined and thought through because packaging often represents the first time a consumer engages with a company or brand.
Mylar itself is already a very high-quality packaging material; but, when it is printed correctly, it becomes like an advertising billboard with a seal on it. While printing Mylar bags there is a balance between the durability of the printed materials, clarity of the images, accuracy of colors, and meeting regulatory requirements, while at the same time creating a bag that feels high-quality to the consumer when they pick it up. Many Mylars bag printers do not produce a quality product; but, those who are experienced in Mylar bag printing know how to achieve this balance while still producing a high-quality product compared to commodity-based packaging solutions.
How to Print on Mylar Bags: Digital Printing vs Gravure Printing
The printing process for Mylar bags is quite different from that of paper or label printing because they require specialized equipment and processes that have been designed specifically for flexible films. The surface of a Mylar bag is non porous, heat sensitive (sometimes even metallic) so therefore the way that they are printed and the way that they hold ink are equally important to the actual design elements on the bag itself.
Digital and gravure printing are the two most common methods of printing on Mylar bags and both are widely proven to produce exceptional results on Mylar, however they both produce for slightly different types of brands and production volumes.
Digital Printing on Mylar Bags
With industrial digital presses capable of printing on flexible packaging films, digital printing is one of the easiest ways to print Mylar bags, particularly if you are looking for a short run or custom project. Digital printing utilizes an inkjet printing process, which means that the inks are applied directly from the printer onto the Mylar without the need for metal plates or cylinders.
Printing typically begins with a layer of white ink. Since Mylar can be either reflective or semi-transparent in nature, the application of white ink to create a base will help ensure that the colours printed on top of the white remain true-to-colour and bold. After the application of the white ink layer, the CMYK inks will be printed in precise passes, after which they are dried with instant heat or UV curing. Once the printed materials are cured, they become resistant to smearing and surface abrasions.
When you are looking for lower minimum order quantities, fast turnarounds, or several variations of design, digital printing is an excellent option. Start-ups, seasonal drops, limited-edition products, and brands testing new packaging concepts are some examples where digital printing is regularly used. Digital printing continues to improve, but in some instances it can be slightly inconsistent when printing large amounts of product compared to gravure printing.
Gravure Printing on Mylar Bags
Gravure printing is the least expensive way to produce large quantities of printed Mylar bags. Each cylinder is made from an engraved metal and prints separate colors of Diana ink on the Mylar film with high precise and consistent results. The first step of the Gravure process is engraving, where the cylinders are made according to the final artwork or design. Each cylinder is used for a different color and applied to the Mylar at high speeds in order to create the finished product.
The process starts with the cylinders being engraved according to the final artwork and in the correct size. When printing, the film moves at a relatively quick speed through the cylinders as the cylinders apply their colored ink layers in proper order. When needed, an initial layer of white ink is applied, followed by colored ink that is then dried and cured before going back through the cylinders to apply the next layer of ink.
Gravure printing results in sharp detail and smooth gradients with consistent color and are the preferred method of printing for national retail brands, as well as for production runs involving a very large number of pieces. While Gravure does have the highest upfront cost and minimum order quantity due to the fact that you must create each cylinder to produce the final product, many people still choose to use this type of printing.
Laminating and Finishing the Printed Film
Typically you will see the Mylar Graphic film printed via gravure or digital print then laminated. Upon laminating, your ink will now be sealed between the lamination layers, giving you a barrier against scratching, moisture, and chemicals all while allowing for finishing options such as matte, gloss, soft touch or with a holographic effect.
Once complete, the Mylar film will be converted into bags by cutting and forming. Depending on your end use of the custom mylar bags, features could include resealable zipper closures or tear notches, hang holes, and/or areas for heat sealing. Paying attention to how you print on the Mylar film during the process will enable you to print where your seal and fold will not negatively impact artwork quality.
Choosing the Right Printing Method
The digital printing method is preferred for its speed, flexibility, and lower cost upfront. When producing large quantities of printed materials with a consistent image quality, gravure printing is the preferred method.
Choosing the appropriate method of production can avoid over-spending or sacrificing quality. Knowledge of how each production method functions will assist a brand’s purchasing decisions.
At Brandmydispo, we utilize both digital and gravure printing strategically based on each brand’s requirements such as volume, lead time, and design goals. In addition to producing quality packaging that is able to perform as intended, understanding the process behind printing Mylar bags will assist in producing Mylar bags that look professional.
Designing for Print, Not Just for Looks
A good printed Mylar bag design begins well before ink is ever applied to any type of substrate. Color behaves differently with metallic representations than it does with electronic ones. Additionally, when printing white on metal substrates, the proper amount of flood must be applied (and/or perhaps layered) while maintaining clarity of the print job. Likewise, the black color must be designed in such a way that it appears to be rich without being overprinted and eliminating details. Further, when printing very small typefaces, the typography must survive during the effectiveness of heat seal and/or shipping.
As a result, a designer must be aware of how varying finishes can influence your design when printed. A matte finish can help reduce glare and provide an increased presence of minimalistic branding. Contrarily, a gloss finish can exaggerate saturation and contrast. Holographic finishes can produce a seemingly animated or 3D layered visual effect, provided that you have adequately planned for an adequate amount of ink used to produce the effect, thus adding visual enhancement, rather than detracting from visual impact. Good designers possess the knowledge of how to strike the right balance between having an abundance of visual presence and demonstrating restraint visually.
The Printing Process That Makes It All Work
Every great printed Mylar bag has an exact process of printing behind it. High resolution printing allows for bright and clean edge definition, as well as smooth color gradients on bags. To keep the color locked into the film so it can be printed without being scuffed or depleted, proper ink curing must be performed. For multiple layer designs on thousands of bags, registration must be exact to align with each design layer perfectly.
Brandmydispo approaches printing with consistency in production. A single great sample is useless if all of the rest of the run varies in color and or alignment compared to that first sample. Proper process control from start to finish ensures that both the first and final bags in the run have identical colors and looking quality. This is of great importance for brands that will be transitioning from small batch production to distribution in retail stores.
Finishes, Textures, and the Feel of Quality
The tactile experience of Mylar sack printing is one of its most underappreciated aspects. Customers will experience the package first before they will read the package. A silky smooth matte surface conveys a sense of luxury. A durable, thick gauge conveys the idea that the product is fresh and protected. Spot-gloss over matte selects a specific area to bring attention to, typically either the logo or the product name.
These details are more than cosmetic. These details build trust. When the package has a substantial feel and delivers an intentional design, customers will subconsciously perceive the quality of the product as being high. Printing is not just a means of visual communications; but rather a means of sensory branding.
Printing for Protection and Performance
Promoting the contents of printed mylar bags is very much a function of how well they are printed on works. The ink systems, lamination layers, and barrier coatings used to print Mylar bags all provide layers of protection for the products inside from moisture, oxygen, & ultraviolet light (UV) and will significantly affect the overall performance of each product if they are poorly constructed with inadequate printing choices or damaged from a poor seal.
At Brandmydispo, the decision regarding how to print bag(s) is done by considering the individual bag(s)’s real-world applications. The quality of the seal, tear, & way bag holds up after being shipped and handled in a retail store are very important factors that must be adhered to when printing a mylar bag(s). The location of the artwork must be taken into consideration when placing bags with zipper zones and heat seal areas, which may help with the overall quality of the printed design once the bag is filled.
Custom Printing at Lower MOQs Without Cutting Corners
Jose recently said that there was a lot of illegal activity due to excessive size. Small and medium-size producers previously were forced to only use generic type products in bags. By creating lower minimum order quantities that do not affect print quality and specifications, Brandmydispo has changed how producers view themselves.
As a result, your brand will be seen as a leader from day one within your category. Additionally, many companies now have the potential to experiment with new product configurations, creating limited run products for special events and opportunities, all while remaining affordable. And not be forced to keep using the same designs.
Ultimately, printing can provide your company with additional opportunities for growth and development, rather than hindering your performance.
Why Printing Is the Heart of Modern Packaging
Products in saturated markets seldom sell based on just their characteristics; they are typically sold via the package before anything else. The Mylar bag must convey Trust, Compliance, Quality, and Personality, and do so within a moment’s time through the print on the surface. Because of this, printing is much more than an afterthought; it is the basis for any modern package strategy.
The art of printing custom Mylar bags comes from understanding that each choice you make with respect to how a Mylar bag is printed will create an impression. A combination of ink density, finish selection, material thickness, and disciplined design will create a completed bag, which enhances the experience of the end user of that product, not just serving as a physical enclosure for the product contained within.
Brandmydispo believes in Mylar bag printing as a long-term investment in brand equity. As a result, we develop packaging that works, protects, and persuades together to achieve an overall goal of building better brands.
