“Packaging can make or break your sales.” These phrases seem harsh, but they are true. Getting the proper product packaging is essential for every business. Your packaging drives customers to choose your product or move on to other options.
Mylar and rigid packaging have become the most preferable and effective option for businesses across all industries. Yet, choosing between the two can be pretty challenging. Read this post completely to know which one you should choose, depending on your product’s and customers’ needs!
Overview of Mylar and Rigid Packaging
When customers open a package, its elements set the tone for their experience with your product and brand. Small differences in texture and material can send a powerful message. Thus, you should never ignore the power of packaging. So, before deciding between Mylar vs rigid packaging, let’s explore them!
What Is Mylar Packaging?
Mylar packaging has a fascinating history. In 1952, DuPont first used the trademark Mylar® for plastic film packaging. Mylar quickly became a game-changer and became famous as the most flexible packaging.
What makes Mylar packaging unique?
The polyethylene terephthalate (PET) material (a metal and plastic mixture) is the fantastic material of this packaging. This material keeps various products fresh with its unique, excellent barrier properties against moisture, oxidation, chemical reactions, air, heat, and light.
The Manufacturing Process of Mylar Bags
The manufacturing process of Mylar bags starts by stretching PET resin into a biaxial direction alongside two axes. The next step is to combine this film with aluminum foil (low oxygen transmission rate), which exudes reflection. Then, the combination of the aluminum foil-coated polyester resin film is heated at 200°F temperature to get a smooth and flat surface.
Thanks to Mylar’s flexible nature, you can customize it in different shapes, sizes, styles, thicknesses, and colors. The standard thickness of a Mylar bag is 3 mils, but depending on your product needs, it can be customized up to 8 mils.
Key Features
Mylar bags stand out for their innovative key features, including:
- Non-porous feature
- Moisture and oxidation resistance
- Lightweight
- Highly flexible
- Resistant to punctures and tears
- Budget-friendly
Besides, the bags are also heat sealable to create an airtight environment, protecting products from exposure to air, moisture, and light. Overall, the excellent barrier properties of the bags ensure your products remain fresh for years. Moreover, the ease of customization, including designs, printing, and seal type, makes Mylar popular for commercial and personal use. Even better, you can get accurately sized Mylar bags according to your needs.
The Popular Types
The high flexibility of Mylar packaging bags makes it easier to design the bag in a unique style and type. Depending on your packaging needs, you can choose from the popular types below:
- Stand Up Pouches: Featuring a sturdy bottom gusset, these pouches are visually appealing
- Die Cut Mylar Bags: The bags have precise cuts that prevent gaps or creases along the sides.
- Spout Pouches: Come with a resealable spout for easy and clean pouring
- Mylar Ziplock Bags: With a secure zip-lock closure, these bags are easy to open and reseal
- Child-proof mylar bags: Designed with tear and puncture resistance and child-resistant lock
- Smell-Proof Bags: Come with multiple layers to contain the scent of the products
- Mylar Bags with Window: A precise window shape lets customers see your products inside the bags.
Pros and Cons
Mylar packaging is beneficial in many ways, but it is not perfect.
Here are the pros and cons of using this flexible packaging!
Pros
- Moisture Resistant: The moisture resistance of Mylar bags can keep products safe.
- Smell Proof: The bags maintain the freshness and aroma of products
- Recyclability: These bags are made following ISO-certified packaging practices and can be recycled
- Customizability: The bags allow for unique printing and branding customization.
- Compact Storage: They are space-efficient
- Lightweight: The lightweight and sturdy features of the bags reduce shipping costs
- Extended Shelf Life: Mylar material ensures the extended shelf life of products for long-term storage
Cons
- Environmentally Harmful: The plastic used in polyester resin harms the environment
- Expensive: Mylar is costly compared to paper packaging
Uses of Mylar Packaging in Different Industries
Offering innovative features and advantages, many brands from different industries find it beneficial to use Mylar packaging.
Here are the primary industries where this packaging is preferable:
- Food: The Mylar material is ideal for long-term food storage
- Cosmetics: It protects cosmetic products from contamination and chemical reactions
- Pharmaceuticals: It works well in preserving medicines
- Cannabis: The odor-proof makes Mylar ideal for packing cannabis products
Market Size
The market size for Mylar packaging was estimated at 2.08 (USD Billion) in 2024. In 2025, the industry is expected to grow from $ 2.18 billion to $ 3.30 billion by 2034. Meanwhile, its market CAGR (growth rate) is expected to be around 4.7% during 2025 – 2034.
What Is Rigid Packaging?
The rigid box concept dates back to the 1800s when people used wooden boxes to package expensive products such as jewelry and watches. The packaging encompasses various materials, including cardstock, plastics, glass, and metal. Thanks to its high durability, custom rigid boxes are preferable for products that need an added layer of protection from physical impacts.
The Manufacturing Process of Rigid Packaging
The manufacturing process for rigid packaging depends on the material used. Today, rigid packaging made from plastic uses blow molding or compression molding, while packaging made from cardstock and paperboard uses cutting dies and gluing.
Key Features
This luxurious packaging is ideal for products requiring extra protection during storage and transportation.
Below are the key features that make rigid the best option for many brands:
- Strong and inflexible structure
- Capability to maintain its shape even when empty
- High durability
- Robust product protection
The Popular Types
- Cardboard Rigid Boxes: Along with technological advancements, rigid boxes today are made of cardstock, one of the strongest packaging materials.
- Glass Packaging: Glass packaging provides high-barrier capabilities, accessibility, and classic appeal.
- Tin Containers: Most luxurious makeup, cosmetics, food, and jewelry are packed in tin containers.
- Hard Plastic Packaging: Reusable plastic packaging is used for retail products.
- Glass Jars: Bottles and jars become the primary packaging for cosmetics, medicines, and food items.
Pros and Cons
Like any other product, rigid packaging has pros and cons. Let’s examine them!
Pros
- Reusable: Its reusability influences customers’ purchasing decisions
- Recyclable: Tin, glass, and rigid boxes can be recycled to reduce environmental waste.
- A Memorable Unboxing Experience: Its aesthetic appeal, combined with functional styles, delivers a memorable unboxing experience for customers.
- User-Friendly: This packaging is customizable, and thus, you can make it user-friendly, too
- Stunning Visual Presentations: Its luxurious appeal and sleek texture of rigid packaging create stunning visual product presentations
Cons
- Costly: Unfortunately, this packaging is expensive, and it has higher manufacturing costs.
- Higher Shipping Charges: Rigid packaging is heavier and can lead to higher shipping costs.
Uses of Rigid Packaging in Different Industries
Speaking of the uses, rigid boxes are perfect for different industries, such as:
- Apparel: The boxes improve the value of apparel products
- Electronics: These boxes are protective for fragile and delicate electronic products
- Jewelry: Jewelry pieces look lovelier in tin and rigid boxes
- Health Industry: The cardstock material is perfect for packaging sensitive medications.
Moreover, rigid packaging is versatile and can be customized in any style, including:
- Collapsible packaging style
- Magnetic rigid boxes
- Two-piece packaging style
- And other trendy styles
Market Size
The global market for rigid packaging was valued at $431.97 billion in 2023 and is projected to grow from $452.96 billion in 2024 to $704.24 billion by 2032, exhibiting a CAGR of 5.67% during the forecast period.
Flexible Packaging vs Rigid Packaging: Which One to Choose?
So, what is the difference between rigid and flexible packaging?
Although both Mylar and rigid packaging are preferable, they have some differences. Which one should your business choose?
Considering your packaging is the first thing that connects your product with customers, you can never neglect the importance of selecting the proper packaging for your business.
There are some factors to consider when choosing between the two; let’s check them out!\
- Cost
Rigid packaging has higher manufacturing costs. Its material is more expensive than Mylar. A small rigid box might cost $1- $5, while a Mylar bag costs only a few cents.
- Durability
Rigid packaging wins in durability. This packaging offers supreme product protection during display and shipping. Meanwhile, Mylar packaging is perfect for preserving products from moisture.
- Aesthetics
Mylar (flexible packaging) represents affordability and convenience, whereas rigid packaging signifies elegance.
- Customers’ Preferences
If your customers expect to see your products in a stylish presentation, you should go for rigid packaging. Meanwhile, Mylar bags will be perfect if your customers focus on long-term usage.
- Sustainability
Mylar is a synthetic material that might not be as environmentally friendly as rigid packaging. For example, cardstock and paperboard materials used to make rigid boxes are recyclable and have a lower carbon footprint.
- Shipping
Mylars’ lightweight nature can reduce shipping costs. Rigid, on the other hand, is heavier and will cost more in shipping.
To make it easier, have a look at the comparison table below!
| Feature | Mylar Packaging | Rigid Packaging |
| Cost | More affordable | More expensive |
| Durability | Perfect for preserving products, but less durable | Offer supreme product protection |
| Aesthetics | Focus more on user-friendly | Luxurious & elegant |
| Customers’ Preferences | Ideal for customers who prefer a stylish presentation | Perfect for customers focus on long-term usage |
| Sustainability | Not as eco-friendly as rigid packaging | Recyclable and eco-friendly |
| Shipping | Can reduce shipping costs | Cost more in shipping |
Wrapping Up
Undoubtedly, Mylar and rigid packaging have become the most preferred and practical options for businesses across all industries. However, choosing between the two can be challenging. Hopefully, our in-depth overview of Mylar vs. rigid packaging above helps you decide which is best for your business.
Still confused? You can contact the experts at Custom Box Makers for more guidance!
FAQs
What is Mylar packaging made of?
Mylar packaging is made of polyethylene terephthalate (PET), a metal and plastic mixture that can keep various products fresh for longer.
What is rigid packaging made of?
Rigid packaging encompasses various materials, including cardstock, paperboard, plastics, glass, and metal.
What type of product can be packed in Mylar packaging?
Mylar packaging is ideal for packing and preserving various products, including food items, cosmetics, pharmaceuticals, and cannabis.
What products are best to be packed in rigid packaging?
Rigid packaging is perfect for high-end products like apparel, electronics, jewelry, and health products.
Which one offers better protection?
Rigid packaging offers supreme product protection during display and shipping. Meanwhile, Mylar packaging is perfect for preserving products from moisture.
Which one is more affordable, Mylar or rigid packaging?
Mylar packaging is more affordable than rigid packaging.
