Mylar Bags for Freeze-Dried Food: What to Know

Freeze-dried food requires packaging that is highly resistant to moisture, oxygen, light, and external humidity. Mylar bags are commonly considered for this purpose because multilayer structures with polyester, aluminium foil or metallized film, and a heat-sealable inner layer are associated with strong barrier performance. The right structure, thickness, sealing method, and storage conditions should be considered before a packaging format is selected.

What Are Mylar Bags for Freeze-Dried Food?

The term Mylar generally refers to biaxially oriented polyethylene terephthalate (BOPET or PET) film. In food storage applications, the term is often used for laminated pouches rather than a single PET layer. A typical structure may include an outer PET layer, a foil or metallized barrier layer, and an inner polyethylene-based sealant layer. The exact barrier properties depend on the complete laminate, film thickness, seal quality, and manufacturing specifications.

Mylar Bags for Freeze-Dried Food: Benefits and Considerations

Several factors should be considered when Mylar structures are used for freeze-dried food, including moisture, oxygen, light, aroma, puncture resistance, and storage conditions. Low moisture content makes freeze-dried foods sensitive to humidity, while oxygen exposure may affect flavour, aroma, colour, and quality. Aluminium foil or metallized layers are often included for stronger light and gas barriers, while film thickness and complete laminate construction are reviewed according to handling and storage requirements. WVTR and OTR specifications, along with ASTM F1249 and ASTM D3985 testing, may be reviewed for barrier performance, while ASTM F88/F88M is associated with seal strength. For more information on Mylar Bags for Freeze-Dried Food: Benefits and Considerations, explore the right material and pouch specifications for your product.

The Sealing and Oxygen Absorbers On Mylar Bags

Heat Sealing

A reliable heat seal is important for maintaining package integrity. The seal area should remain clean and free from food particles before sealing, while suitable temperature, pressure, and dwell time should be established for the selected sealant layer. ASTM F88/F88M is commonly used for seal-strength testing. Seal quality should be checked through appropriate package-integrity procedures rather than judged only by appearance.

Oxygen Absorbers

Oxygen absorbers are frequently included in long-term freeze-dried food storage. The absorber capacity should correspond with package volume, food quantity, residual air, and storage conditions. Manufacturer specifications should be followed because an incorrect capacity may affect the intended oxygen reduction level.

Mylar Pouch Styles for Freeze-Dried Food

Stand-Up Mylar Pouches

Stand-up pouches are suitable for retail presentation and household storage where upright positioning is preferred. A flat bottom or gusseted base may be incorporated according to the required filling volume and presentation.

Three-Side Seal Pouches

Three-side seal pouches have seals along three edges, with the remaining opening used for filling and final closure. This format is often considered for compact portions, samples, meal packs, and space-efficient storage.

Gusseted Mylar Bags

Gusseted bags include expanded side or bottom panels for greater filling capacity. This structure is commonly considered for larger quantities where additional internal volume and upright positioning are required.

Vacuum-Sealed Pouches

Vacuum packaging involves air removal before sealing. This approach may be considered where reduced residual air is part of the storage strategy, although compatibility with the freeze-dried food and the selected film structure should be reviewed first.

Storage Conditions and Shelf Life

After sealing, freeze-dried food should be kept in a cool, dry, and dark environment. Excessive heat, humidity, direct sunlight, and repeated temperature changes may affect food quality and package integrity. The storage period should be established through product-specific testing and suitable packaging validation rather than based solely on the material name.

Food Safety and Regulatory Requirements

Food-contact packaging should be assessed according to the intended food, processing conditions, storage environment, and market. In Canada, applicable requirements may involve the Food and Drugs Act and Food and Drug Regulations, Safe Food for Canadians Regulations, and Consumer Packaging and Labelling Act and Regulations. In the United States, applicable food-contact requirements may fall under Title 21 of the Code of Federal Regulations. Documentation for films, coatings, adhesives, inks, and sealant layers should be reviewed before commercial use.

Recycling and Sustainability Considerations

Many traditional Mylar food pouches contain bonded layers of polyester, aluminium or metallized film, and sealant materials. Such multilayer construction may create challenges for conventional recycling systems. Mono-material structures, recycled-content options, and other lower-impact formats are being developed, but barrier performance and food-contact suitability still need to be considered alongside recycling requirements and local collection infrastructure.

“Customers will occasionally buy products not because they want them but because of how they are presented to them.” — James Clear

Conclusion

Mylar bags are widely considered for freeze-dried food storage because suitable multilayer structures offer strong resistance to moisture, oxygen, and light. For custom freeze-dried food packaging options, Universal Packaging Inc offers packaging solutions based on different product requirements. However, storage performance depends on the complete laminate construction, film thickness, sealing, oxygen management, food characteristics, and storage conditions, which should be reviewed before a final packaging specification is established.

Universal Packaging Expands Its Presence In Vancouver

Universal Packaging has established a new location in Vancouver, adding another base to its growing operations across Canada. The Vancouver location marks an important step in the company's national expansion, while a new location in Mississauga is planned to open soon as the next phase of growth. Managing Director Daniel James stated, "Our continued expansion across Canada brings us closer to customers, with advanced printing technology supporting flexible packaging solutions and ongoing growth."

The Vancouver expansion comes as businesses across the region continue to strengthen their operations and pursue new growth opportunities. "Strengthening manufacturing in the country means strengthening our economy, support for our workers and our prosperity for generations to come," said the Honourable Mélanie Joly, Minister of Industry.

With Vancouver now established as part of its Canadian operations, Universal Packaging is preparing for its upcoming Mississauga location. The new location will further extend the company's regional reach and bring custom packaging solutions closer to customers across Ontario.

Frequently Asked Questions

Are Mylar bags suitable for freeze-dried food?

Suitable food-grade Mylar laminate structures are commonly considered for freeze-dried food, particularly where strong moisture and oxygen barriers are required.

Are oxygen absorbers needed with Mylar bags?

Oxygen absorbers are often considered for extended storage, but the required capacity depends on package volume, food quantity, residual air, and storage conditions.

What thickness should be used?

The appropriate thickness depends on the food, handling conditions, puncture risk, and storage period. Barrier specifications should be reviewed together with thickness rather than relying on thickness alone.

Are Mylar bags recyclable?

Recyclability depends on the complete material structure and local recycling infrastructure. Multilayer foil-based pouches may have limited compatibility with conventional recycling systems.

Are Mylar bags waterproof?

Suitable multilayer structures have strong resistance to water vapour, but moisture-barrier performance varies by laminate construction and seal quality.