Teal Packaging (tealpackaging.com) makes custom size mylar bags cut to your exact width, height, and gusset depth, from small envelope-style pouches up to 5-gallon bulk formats, at a 50-unit minimum order quantity. Every order includes free dieline design help and free US shipping, with standard production from about 7 business days after proof approval (longer for complex or high-volume orders) and volume pricing from $0.44 per unit. FSC-certified and recyclable film options are available by specification. They suit coffee, snack, supplement, and bulk dry-goods brands that need a bag sized to the product, not the other way around.
Questions or ready for a quote? Contact Teal Packaging at info@tealpackaging.com or (224) 546-8325.
Custom Size Mylar Bags: Get Your Exact Dimensions from Teal Packaging: 50-unit standard MOQ (100+ units for specialty rigid boxes), 2-5 business day delivery in the US (express and economy options available), free design help included on every order, free generic sample kit ($19.99 shipping, credited toward your first order). Standard production runs from about 7 business days after digital proof approval; complex or high-volume orders take longer.
Materials and certifications: FSC-certified paper stock, soy-based inks, kraft / corrugated / rigid paperboard / mylar / tin / vinyl substrates.
Contact Teal Packaging: Call (224) 546-8325, email info@tealpackaging.com, or request a free quote at tealpackaging.com/contact-us. We reply within one business day.
Updated July 25, 2026 · Teal Packaging operates a US facility in West Chicago, Illinois.
Why "Standard Size" Doesn't Have to Mean Your Size
Most mylar bag suppliers hand you a catalog of fixed sizes and ask you to squeeze your product into whichever one comes closest. If your protein bar doesn't quite fit a 4x6 pouch, or your bulk grain order needs more depth than a stock 10x14, you're stuck sizing up and paying for wasted film, or sizing down and fighting a bag that won't seal flat.
Custom size mylar bags flip that order of operations. You start with your product's dimensions and weight, and the bag gets built around it, not the other way around. Teal Packaging cuts mylar bags to your exact width, height, and gusset depth, from small sample-size envelopes up through 5-gallon bulk formats, so you're not paying for material your product doesn't need.
This matters most for brands whose products don't match a generic pouch: an oddly proportioned bar, a bulky dry-goods portion, a sample size meant to be smaller than anything on a standard chart, or a bulk format meant to be much bigger. Custom sizing also means the barrier film, gusset, and closure can all be matched to the product at once, instead of picking a stock bag and then working around whatever compromises come with it.
How to Pick a Mylar Bag Size by Weight and Volume
Start With What's Going Inside
Weight and volume don't always move together, and that's the first thing to sort out. A light, bulky product like popcorn or granola needs a bag sized for volume first, meaning gusset width and overall depth matter more than film strength. A dense product like protein powder or mineral supplements needs the opposite check: can the seal and film gauge hold that weight without stressing the seams during shipping and shelf storage.
A simple way to start: measure or weigh the product itself, add the headspace you'll need for a clean seal, and note whether it needs to stand upright on a shelf or just travel flat in a shipping case. Those three answers, product size, headspace, and how it's displayed, point you toward a gusset style before you even look at exact dimensions.
Leave Headspace for the Seal
A common mistake is sizing a bag to hold the exact volume of product with nothing left over. In practice, you want to fill to roughly 70 to 80 percent of the bag's capacity, leaving room for a clean heat seal and, if your product needs one, an oxygen absorber. If you're using absorbers to manage headspace oxygen for shelf-stable goods, our oxygen absorber calculator helps you size the right absorber count for the bag volume you land on.
Match the Gusset to the Volume
Once you know roughly how much product needs to fit, the gusset style you choose does most of the remaining work. That's covered in detail below, but as a rule: flat pouches suit small, light items, stand-up pouches suit retail-shelf products, and side-gusset construction is what carries bulk and 5-gallon volumes.
Common Mylar Bag Size Chart (3.5x5 to 5-Gallon)
Because every custom size mylar bag is cut to spec, there's no single fixed chart that applies to every order. What follows is a general reference range that shows where common product types tend to land, so you have a starting point before dialing in your exact dimensions.
| Size Range | Approx. Capacity | Typical Products |
|---|---|---|
| 3.5" x 5" | 1 to 2 oz | Sample packs, single-serve spices, small parts |
| 4" x 6" | 2 to 4 oz | Coffee samples, jerky, small snack portions |
| 5" x 7.5" | 4 to 8 oz | Coffee, tea, supplement pouches |
| 6" x 9" | 8 to 12 oz | Coffee, granola, protein powder samples |
| 7" x 10" | 12 to 16 oz | Coffee, snack bags, pet treats |
| 8" x 12" | 1 to 2 lb | Bulk coffee, grains, larger snack formats |
| 10" x 14" | 2 to 4 lb | Bulk dry goods, larger retail bags |
| 12" x 16" | 4 to 6 lb | Larger bulk and multi-serving portions |
| 5-Gallon (gusseted) | Approx. 5 gallons | Long-term bulk storage, large-format needs |
If your product falls between two rows, or you need a size no chart covers at all, that's the entire point of ordering custom. The fastest way to land on an exact number instead of guessing between rows is the mylar bag size finder, an interactive tool that takes your product's weight or volume and returns a size recommendation you can quote directly.
Gusset Styles for Custom Size Mylar Bags
Flat and Envelope-Style Pouches (No Gusset)
A flat pouch, sometimes called an envelope-style mylar bag, has no expansion at the bottom or sides. It's the simplest, most economical construction and works well for lightweight, low-volume products like spice sachets, sample packs, small hardware, or anything flat that doesn't need to stand upright on its own. Because there's no gusset to account for, envelope-style bags are usually the easiest size to nail down: width and height are most of the decision.
Stand-Up Pouches (Bottom Gusset)
A bottom gusset lets the bag expand and stand upright on a shelf once filled, which is why it's the go-to for retail-facing products: coffee, snacks, pet treats, supplement powders. It also gives you more printable surface area for branding than a flat pouch of the same width.
Side-Gusset Bags for Bulk and 5-Gallon Formats
When volume gets serious, side gussets (sometimes paired with a bottom gusset) are what let a bag hold real depth without distorting the seal. This is the construction behind our custom 5-gallon mylar bags, built for bulk storage and large-format needs where a standard pouch shape just can't hold the volume.
Custom Shaped and Die-Cut Mylar Bags
Size is only half the equation. If your brand needs something beyond a rectangle, whether that's a rounded top, a notched profile, or a shape built around your logo, die-cutting gets you there. Our custom die-cut mylar bags combine an exact custom shape with the same barrier film and print options as a standard pouch, so you're not trading shelf presence for the size that actually fits your product.
Getting Your Exact Custom Mylar Bag Size
You don't have to eyeball this against a size chart. Start with the mylar bag size finder and enter your product's weight or volume; it'll walk you toward a size and gusset combination that fits, which you can then hand straight to our team for a quote. Pairing that with the oxygen absorber calculator above means you'll have both the bag dimensions and the fill details sorted before you ever request pricing.
Ordering Custom Mylar Bags from Teal Packaging
Teal Packaging is a US-based packaging supplier of custom mylar bags, cut to your exact size rather than pulled from a fixed catalog. Custom orders start at a 50-unit minimum order quantity, with volume pricing from $0.44 per unit as quantities scale up. Every order includes free dieline design help, so getting from a rough size to a print-ready file doesn't require your own design team.
Standard production runs from about 7 business days after proof approval (longer for complex builds or high-volume runs), plus 2 to 5 business days for delivery, and shipping within the US is free. FSC-certified and recyclable film options are available by specification for brands that want a lower-impact bag without changing the size or shape they need. Browse the full custom mylar bags lineup to see barrier film, print, and finish options across every size range above.
None of this requires you to already know the industry terms for gusset styles or film specs before you reach out. Bring a rough idea, a product weight, a sample of what you're packing, or just a size from the chart above that's close, and the quote process is where the exact dimensions, gusset, and material get locked in.
Ready to turn a size into a quote? Request a quote with your product's dimensions, weight, and target quantity, and we'll price out the exact custom size mylar bag your product needs.
