Custom Printed Foil Matt Mylar Bag with Zipper (28 g)Custom Shape Pouches
Custom shape pouches are die-cut to an outline of your own rather than a rectangle: a bottle silhouette, a rounded top, a shaped shoulder. We build them in foil and PET/PE with resealable zippers and smell-proof structures available. Each outline needs its own cutting tool, paid once and held for repeat orders, so the shape is worth it where it is the shelf differentiator and a printed rectangle would not be. Confectionery and small-format brands are the usual buyers.
In this range12 products
Minimum orderFrom 1,000 pieces
SamplesStock samples free
Lead time15-25 days after approval
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Custom Printed Foil Matt Mylar Bag with Zipper (28 g)
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Custom Printed Foil Mylar Bag for Odour and Moisture Sensitive Dry Goods No. 2 -
Custom Printed Foil Mylar Bag with Zipper – Smell-Proof (5 g) No. 3 -
Custom Printed Foil Mylar Bag with Zipper No. 2 -
Custom Printed Matt Mylar Bag with Zipper – Smell-Proof (5 g) -
Custom Printed Matt Mylar Bag with Zipper (5 g) -
Custom Printed Mylar Bag – Smell-Proof (5 g) -
Custom Printed Mylar Bag for Odour and Moisture Sensitive Dry Goods (5 g) -
Custom Printed Mylar Bag with Zipper – Smell-Proof (5 g) -
Custom Printed Mylar Bag with Zipper No. 4 -
Resealable Die-Cut 3.5 g Mylar Pouch for Confectionery -
UV Printed Die-Cut 3.5 g Mylar Pouch, Smell-Proof
How a custom shape pouch is built
Die-Cut to an Outline of Your Own
A custom shape pouch is a normal laminate cut to a silhouette rather than a rectangle: a bottle profile, a character, a fruit, a logo made three-dimensional. The construction underneath is unchanged — it is the die that is bespoke, and the seal that has to follow the outline without leaving a weak point.
What Makes a Shape Work
- No sharp internal corners. They start tears. Every reflex angle gets a radius, and we will tell you where your drawing needs one.
- Enough seal land everywhere. The seal follows the outline, so a narrow neck in the silhouette becomes a narrow seal unless the shape allows for it.
- A flat area for the legal panel. Barcodes and nutrition text do not sit on a curve.
- A base that still stands, if it has to. A shaped pouch can take a gusset, but the outline has to leave room for it.
What It Costs
A cutting die per shape, once, reused on every repeat. Beyond that it prices like any other pouch of the same size and structure. The die is cheaper than most people expect; the design time to make the shape work is the part worth budgeting.
How We Get There
Send a drawing, a sketch or even a photograph of the silhouette you want. We draw the dieline, mark where the seal and the safe area fall, and return a 3D mock-up of the pack standing before any tooling is cut. See the artwork and dieline service for what happens at each stage.
Narrow it down
Where Custom Shape Pouches Sits in the Range
The numbers are how many packs in this range are also in that one, counted from the catalogue rather than chosen by hand.
The Materials It Runs In
What This Range Is Used For
Frequently asked
Specifying Custom Shape Pouches: The Questions That Decide It
What can be cut into a shape?
Any of our standard constructions. The laminate and the seals are unchanged; it is the cutting die that is bespoke and the seal that has to follow your outline.
What does the cutting die cost?
One die per shape, quoted with the job and reused on every repeat at no further charge. It is usually less than people expect — the design time is the bigger line.
Are there shapes you cannot make?
Sharp internal corners start tears, and a very narrow neck in the silhouette leaves too little seal land. We will tell you which parts of a drawing need a radius rather than refuse the shape outright.
Can a shaped pouch still stand?
Yes, with a base gusset, provided the outline leaves room for one. A shape that tapers to a point at the bottom cannot, and we will say so before tooling.
Where do the barcode and legal text go?
On a flat area away from curves and seals. Finding that area is part of drawing the dieline, and it sometimes changes the silhouette slightly.
Can it take a zipper or a spout?
Both, as long as the outline gives a straight run of seal for the zipper or a clear weld area for the fitment.
What do you need from me to start?
A drawing, a sketch, or a photograph of the silhouette. We draw the dieline, mark the seal and safe areas, and return a 3D mock-up before any tooling is cut.
Will it run on my filling line?
Pre-made shaped pouches need a filler that grips them. Send the machine make: some shapes need a gripper flat added to the outline, which is easier to design in than to retrofit.
Is the minimum order higher for a shape?
No, still 1,000 pieces per artwork. The die is the only additional cost and it is a one-off.
How much does the shape actually help?
On a shelf where every competitor is a rectangle, a silhouette is the cheapest distinctiveness available. It is worth least where the pack is bought online and seen as a photograph.