Mylar vs Rigid Packaging Pick the Right One

The right product packaging benefits your business in many ways like protecting products, branding, and attracting customers with aesthetic appeal. Mylar and rigid packaging are common choices for consumer-packed good brands. But choosing between these two is quite tricky because both have immense significance. Read this blog for in-depth knowledge about mylar vs rigid packaging to choose what suits your packaging and branding needs. Continue reading!

An Overview of Mylar Packaging

Mylar is known as flexible packaging because it is made from a flexible film polyester resin. What makes mylar packaging unique is its great barrier properties against moisture, oxidation, chemical reactions, air, heat, and light. The flexible nature of mylar bags supports printing and customization. Mylar packaging can be customized in different shapes, sizes, styles, thicknesses, and colors. The standard thickness of mylar bag packaging starts from 3mil but can be customized up to 8 mils according to your product needs. 

Mylar Packaging Market Size

The immense significance of mylar packaging in major industries like food, cosmetics, and pharmaceuticals is the reason for its high market demand. In 2021, the Mylar market was valued at $10.7 billion. And now it is expected to reach  $20.4 billion by 2031, growing at a CAGR of 6.9% to 2031.

Manufacturing Process of Mylar Bags

First of all, a flexible film is prepared from polyester resin. Then, it is stretched into a biaxial direction alongside two axes. Then aluminium foil is coated for added protection and a reflective surface. Afterwards, 200°F temperature is applied to the aluminium foil-coated polyester resin film for smooth and even surface. Different closing mechanisms are incorporated. Lastly, you can get it printed in your desired design that aligns with your brand personality and product needs. 

Types of Mylar Bags

The types of mylar packaging depend on the style and design you choose for your product packaging. However, some popular types of mylar bag packaging are as follows:

• Ziplock Mylar Bags
• Smell-Proof Mylar Bags
• Odd-Shaped Mylar Bags
• Stand-Up Mylar Pouches
• Child-Resistant Mylar Bags
• Vacuum-Sealed Mylar Bags
• Flat-Bottom Mylar Pouches
• Mylar Bags With Windows

Advantages and Disadvantages of Mylar Bag Packaging

Mylar packaging is beneficial in many ways but it does not imply that it is perfect. It has amazing benefits with a few cons. Here’s a brief comparison of the advantages and disadvantages of mylar bags:

Advantages of Mylar Packaging

Moisture Resistant: Mylar bags are famous for their moisture resistance, which keeps products safe.

Smell Proof: Mylar bags maintain the freshness and aroma of products without stinking. 

Recyclability: Mylar bags can be recycled and made following ISO-certified packaging practices.

Customizability: Mylar packaging is flexible, supporting printing and customization for branding. 

Compact Storage: Mylar packaging occupies less space, unlike rigid boxes. 

Lightweight: The lightweight and sturdy mylar packaging reduces shipping costs. 

Prolonged Shelf Life of Products: Ensure the extended shelf life of products for long-term storage.  

Disadvantages of Mylar Packaging

Environmentally Harmful: Plastic is used in the form of polyester resin, harming the environment. 

Costly: Compared to flexible paper packaging, mylar is expensive. 

4 Major Industries Using Mylar Bags

Mylar packaging acts as a barrier against moisture, oxidation, and air to ensure products’ prolonged shelf life. This is why it is used in the following top 4 major industries:

Food Industry

Mylar bags keep the food safe from moisture, heat, light, air, and other external damages. They are known for ensuring long-term food storage. Some popular food items packed in mylar bags for long-term storage are as follows:

• Spices
• Snacks
• Pet Food
• Dry Fruits
• Ketchup & Similar Items

Cosmetic Industry

Mylar bags protect the cosmetic product from contamination and chemical reactions. Moreover, some cosmetic and skincare tools are also packed in mylar bags. The following products are mostly packed in mylar bags:

• Gels
• Scrubs
• Eyelash Curler
• Powdered Masks
• Liquid Face Masks
• Blackhead Remover

Pharmaceutical Industry

Mylar packaging is used in the pharmaceutical industry to preserve medicines. Because medicines need to be protected from humidity and chemical reactions.  The following are some pharmaceutical products packed in smell-proof mylar bags for optimum protection:

• Tablets
• Capsules
• Cannabis
• Injections
• Powdered Medicines

Toiletries and Cleaning Agents

Household cleaning products are packed in mylar bag packaging because they are usually used for long-term storage. The following are some toiletries and cleaning items packed in the spout mylar bags:

• Detergents
• Hand Wash 
• Dishwashers
• Glass Cleaner
• Toilet Cleaner
• Vehicle Wash & Wax

An Overview of Rigid Packaging

Rigid packaging can be in any rigid form like tin, plastic, and boxes. Boxes are made from rigid stock. Metallic rigid packaging is used from tinplate-coated steel. Rigid packaging is used for packing, displaying, and shipping high-end products. It can be recycled and reused. 

Rigid packaging supports printability and customization, helping you portray the brand story compellingly. Rigid boxes and containers are used for luxury and premium products to improve their perceived value, which makes your products more desirable.

Types of Rigid Packaging

The types of rigid packaging depend on the material, style, and design. Some material-based rigid packaging options are as follows:

Glass Jars: Bottles and jars are used as primary packaging for cosmetics, medicines, and food. 

Rigid Boxes: Luxury cosmetics, food, electronics, clothes, and gifts are packed in rigid boxes.

Tin Containers: Most high-end makeup, cosmetics, food, and jewelry are packed in tin containers. 

Hard Plastic Packaging: Reusable plastic packaging is used for retail products. 

Advantages and Disadvantages of Rigid Packaging

Like any other thing, rigid packaging also has some boons and banes. Here’s a brief comparison of the advantages and disadvantages of rigid packaging:

Advantages of Rigid Packaging

Reusable: The best thing about rigid packaging is its reusability, influencing customers’ purchasing decisions. 

Recyclable: Rigid packaging like tin, glass, and boxes can be recycled to reduce environmental waste.

Improved Unboxing Experience: Aesthetic appeal and functional styles of rigid packaging offer a delightful unboxing experience to foster brand loyalty. 

User-Friendly: Rigid boxes, contains, jars, and bottles are more user-friendly. 

Visually Appealing: Rigid packaging is known for its excellent outlook and luxurious appeal.

Disadvantages of Rigid Packaging

Costly: Materials used for rigid packaging are expensive and it has higher manufacturing costs. 

Higher Shipping Charges: Rigid packaging is heavier and can cause higher shipping costs. 

7 Major Industries Use Rigid Packaging

Rigid packaging is a significant player in the luxury market due to its appeal and reusability. The following are the top 7 industries that use rigid packaging, especially for their high-ticket items:

Food & Beverages Industry

Food items like chocolates, sweets, candies, and cakes are packed in rigid boxes and tin packaging to enhance their presentation. Tin packaging also keeps food items safe in the long term.

Fashion Industry

Luxury fashion products like apparel and footwear are mostly packed in rigid boxes to improve products’ perceived value. 

Electronics Industry

Fragile and coarse electronic items are packed in rigid boxes and plastic packaging with bubble wrap to ensure superior product protection. 

Jewelry & Accessories

Jewelry pieces are presented in tin and rigid boxes. High-ticket jewelry items like diamond, gold, or platinum are generally packed in precisely-crafted custom jewelry boxes.

Candle Industry

The candle retail industry uses tin and box packaging for primary and secondary packaging respectively for a premium appeal. Glass candle jars are also used to store candle wax. 

Gift Industry

Luxury gifts are packed and presented in custom rigid boxes for enhanced appeal and superior protection. The sophisticated rigid boxes also improve your gifts’ perceived value while improving customers’ gift-giving experience. 

Cosmetic & Skincare

High-end skincare and cosmetic products are packed in rigid packaging like tin containers, glass bottles and jars, and rigid boxes. Tin and glass packaging is used as primary packaging for luxury perfumes and skin care products.

Difference Between Mylar and Rigid Packaging

Mylar and rigid packaging are reliable depending on the type of your products. Here’s a short comparison between mylar vs rigid packaging, which will help you choose the right one:

Sustainability: Rigid packaging is environmentally friendly as compared to mylar packaging because rigid boxes, tin and glass containers can be recycled and reused. 

Shoppers’ Preferences: Consumers prefer buying products packed in reusable and sustainable packaging, especially food and luxury goods. This is why they prefer buying food products in a reusable tin and rigid packaging. Likewise, your customers expect their high-end products to be packed in luxury rigid packaging. 

Designs: Customers want to explore a variety of different styles and designs of packaging when making purchasing decisions. This is why Mylar would be their preferred choice because it is flexible and can be customized in different styles and designs. 

Cost: Rigid packaging has higher manufacturing costs and its material is also expensive as compared to mylar packaging. 

Strength: Rigid packaging offers superior product protection and enhanced appeal as compared to mylar packaging. It is also reusable and can be used for storage. Therefore, rigid packaging is more durable than mylar packaging bags. 

Which Packaging Should You Choose?

The result of comparing mylar vs rigid packaging depends on your packaging needs, budget, and product nature. When choosing between rigid and mylar packaging, you should understand if you want packaging for products’ long-term storage or luxurious appeal. If you want to keep your products safe for the long term, go with the mylar packaging. However, your choice should be rigid packaging if you want luxury packaging for your high-end products. Choose the packaging that aligns with your product needs, brand personality, and budget.