Mylar is widely used across industries, from food and pharmaceuticals to cannabis and electronics, because of its unique combination of protective properties and visual appeal. Whether you're sealing in freshness, blocking out light and oxygen, or simply creating a premium shelf presence, Mylar films deliver.

Some of the key reasons Mylar is a go-to choice for flexible packaging include:

Exceptional durability: resists tears, punctures, and moisture

High barrier protection: shields products from oxygen, light, and humidity

Outstanding appearance: supports vibrant, high-resolution printing and finishes like matte, gloss, and metallic

What Is Mylar?

Mylar is often used as a catch-all term for shiny, crinkly plastic film, but technically, it refers to a specific type of material: biaxially-oriented polyethylene terephthalate, or BoPET. The name “Mylar” is a registered trademark of DuPont, originally introduced in the 1950s. Since then, it has become a widely used name across the packaging industry for strong, high-barrier polyester films.

Composition and Structure of Mylar Film

At its core, Mylar is made from polyethylene terephthalate (PET), a type of plastic resin. During manufacturing, the PET is stretched in two directions (biaxially oriented), which improves its tensile strength, clarity, and barrier properties. The result is a thin, lightweight, yet incredibly tough film that’s flexible and resistant to tearing or punctures.

Mylar can also be:

• Clear, for visibility and product display
  
• Metallized (MET-PET), which involves applying a thin layer of aluminum for light and oxygen protection
  
• Laminated, layered with other films for added protection, durability, or printability

How Mylar Compares to Other Packaging Films

Material

Barrier Performance

Durability

Printability

Cost

Best Uses

Mylar (BoPET)

Excellent (especially when metallized)

High

Excellent

Moderate

Food, cannabis, pharma, electronics

PET (non-oriented)

Good

Medium

Good

Lower

Labels, basic packaging

MET-PET (Metallized PET)

Superior to PET, light & oxygen barrier

High

Excellent

Moderate

Coffee, snacks, perishable goods

Foil (Aluminum)

Highest barrier

Rigid, can crease

Moderate

Higher

Pharmaceuticals, vacuum-sealed foods

While foil offers slightly better barrier protection in some cases, it’s more expensive, less flexible, and prone to cracking or pinholing. Mylar offers a balance of protection, flexibility, and cost-efficiency, making it ideal for a wide range of applications in flexible packaging.

Why Mylar Is Used in Flexible Packaging

Mylar has become a leading material in flexible packaging thanks to its unique combination of protective performance, durability, and visual versatility. Whether you’re packaging food, supplements, cannabis, or industrial components, Mylar delivers consistent results across critical performance areas.

1. Barrier Properties

One of Mylar’s biggest strengths is its ability to protect products from environmental exposure that could compromise freshness, flavor, potency, or shelf life.

• Moisture Resistance: Mylar creates a strong barrier against moisture, keeping products like snacks, powders, and dried goods dry and crisp. This is especially important for hygroscopic products that absorb water easily (like jerky, tea leaves, and supplements).
  
• Oxygen Barrier: Exposure to oxygen can cause spoilage, rancidity, or chemical degradation. Mylar’s tight molecular structure, and even more so in metallized versions (MET-PET), acts as a powerful shield against oxygen infiltration, extending shelf life and product stability.
  
• Light Protection (especially in MET-PET): Light, particularly UV, can break down sensitive ingredients like vitamins, flavors, and cannabinoids. Metallized Mylar reflects light, offering exceptional opacity and protecting products from photodegradation. That’s a key reason it’s heavily used in cannabis, pharmaceuticals, and premium snack packaging.

2. Durability

Mylar films are engineered for strength and resilience. This makes them ideal for both retail display and shipping environments where packaging may be compressed, dropped, or exposed to rough handling.

• Tear and Puncture Resistance: Unlike foil, which can crack or tear under stress, Mylar remains flexible and tough. This helps protect the product inside while reducing the risk of packaging failure during transit or on shelves.
  
• Heat Resistance and Sealing Capability: Mylar maintains its integrity under high temperatures, making it compatible with heat-seal machines. This ensures strong, tamper-evident seals, which are critical for maintaining freshness and complying with safety regulations.

3. Printability and Visual Appeal

Packaging isn’t just about protection, it’s also your product’s first impression. Mylar excels here too.

• Supports High-Quality Printing (Glossy, Matte, Metallic): Mylar films offer a smooth, stable surface for vivid, high-resolution graphics. Whether you want a glossy premium look, a soft-touch matte finish, or metallic effects, Mylar can be treated or laminated to match your brand’s aesthetic.
  
• Works Well with Digital, Flexo, and Roto Printing: Mylar’s versatility extends to all major printing technologies:
  
  
  
  • Digital for small runs, rapid turnarounds, and multiple SKUs
    
  • Flexographic (Flexo) for mid-to-large scale runs with color consistency
    
  • Rotogravure (Roto) for ultra-high-volume runs with detailed, consistent results

This makes it easy to scale your packaging without compromising quality or brand impact.

How Red Dot Customizes Mylar Packaging

At Red Dot Packaging, we go beyond just supplying Mylar film, we engineer complete packaging solutions tailored to your product, brand, and performance requirements. Whether you're launching a new SKU or scaling up to national distribution, our team makes it easy to build packaging that stands out and performs.

Custom Pouch Styles

Mylar film can be converted into a wide variety of pouch formats, and we offer all of the most popular, and high-performing, styles:

• Stand-Up Pouches: With a bottom gusset that allows them to sit upright on shelves, these are perfect for snacks, coffee, supplements, and more. Strong shelf presence with lots of real estate for branding.
  
• Flat Pouches: Also known as 3-side seal pouches, these are ideal for single-use products, sample packs, or thin-profile items. Lightweight and cost-effective.
  
• Gusseted Bags: Add extra volume for heavier or bulkier products like pet treats, fertilizer, or protein powder. Available with side or bottom gussets depending on your needs.Each style can be customized further with closures, finishes, and specialty features to deliver a high-end experience while preserving product quality.

Specialty Finishes

Visual impact is critical in today’s crowded retail environment. Red Dot offers a wide range of finish options that can be applied to Mylar packaging to help your product pop:

• Matte Finish: Elegant, premium feel that minimizes glare and enhances soft-touch textures.
  
• Gloss Finish: Sleek and shiny, perfect for high-color branding and sharp graphics.
  
• Soft Touch Matte: Velvety feel that adds a tactile experience to luxury goods.
  
• Holographic Effects: Eye-catching light reflection for limited editions, promotional runs, or bold brand statements.
  
• Dual Finish: Combine gloss and matte elements in one pouch to highlight logos, text, or product imagery with added depth.
• These finishes are compatible with all of Red Dot’s printing methods, digital, flexographic, and rotogravure, so your graphics look crisp and professional at any volume.

Functional Features

Great packaging doesn’t just look good, it performs well for both the consumer and the manufacturer. We offer a wide selection of add-on features to improve usability, product freshness, and shelf appeal:

• Zippers: Choose from standard resealable zippers, powder-proof zippers, child-resistant closures, and more. We also offer slider, hook-and-loop, and dog bone styles.
  
• Tear Notches: Make it easy for customers to open the pouch without scissors.
  
• Hang Holes: Available in round, euro, or sombrero styles for convenient retail display.
  
• Degassing Valves: Popular in coffee packaging to allow CO₂ to escape without letting oxygen in.
  
• Laser Scoring & Micro-Perforation: For easy-open experiences and controlled airflow.
  
• Tin Ties & Tape Seals: Great for bakery or dry goods applications where resealability is important but zippers aren’t needed.

These options can be mixed and matched depending on your market and product use case, our team will help you determine what works best.

Conclusion

Mylar has earned its place as a top choice in flexible packaging for good reason. Its superior barrier properties, exceptional durability, and high-end printability make it an ideal material for protecting and promoting a wide range of products, from food and supplements to cannabis, electronics, and industrial goods.

Whether you're looking to extend shelf life, create a standout retail presence, or improve packaging performance, Mylar offers a versatile and reliable solution. From metallized films that block light and oxygen to soft-touch matte finishes that elevate the brand experience, Mylar adapts to your product’s specific needs without compromise.

At Red Dot Packaging, we bring over 40 years of combined technical expertise in flexible packaging and we specialize in helping brands harness the full potential of Mylar. From custom pouch engineering and advanced finishes to sustainable options and rapid prototyping, we provide tailored solutions that bring your vision to life while keeping your product protected and market-ready.

Ready to see what Mylar can do for your brand? Let’s talk. Request a sample or get a custom quote today and discover how Red Dot can help your product stand out and perform.

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