Mylar Vs Rigid Packaging: Differences and Similarities

Packaging has always been a trademark for brands to protect, promote, and sell their products. Depending on the type and nature of the product, packaging varies. For the general public and consumer, packaging is just a container or a box that is displayed on shelves. 

However, the overall science behind packaging is more than just the protection and safety of products. It is a tool to promote, market, and entice customers. In addition, it is also used to boost brand identity, brand loyalty, and brand awareness. 

Among popular packaging choices, mylar and rigid packaging are found abundantly on store shelves. In this post, we are going to compare mylar and rigid packaging, as well as their differences, similarities, benefits, properties, and much more. Let’s get started. 

Mylar and Rigid Packaging Overview

What is Mylar (Flexible) Packaging?

Mylar packaging or flexible packaging is a type of packaging used generally for storing food items made from polyethylene terephthalate film. The material used in manufacturing mylar packaging is due to its durability, flexibility, and transparency. Mylar packaging bags for food storage are ideal for storing edibles due to a number of properties, such as:

Mylar packaging bags are light reflective, puncture resistant, gas impermeable, child resistant, and durable. Mylar packaging is preferred over plastic packaging as it allows zero air to pass through, which is helpful in extending shelf life. 

Also Read:What is a Mylar Bag: Everything You Need to Know

What is Rigid Packaging?

Rigid packaging boxes are normally made of hard materials that cannot be deformed or bent easily. They are used for the protection and safety of sensitive materials such as electronics, beverages, and pharmaceuticals. Rigid packaging boxes are made from corrugated cardboard or paperboard. 

Rigid packaging is quite higher than Mylar packaging, due to its material, weight, and size. However, when it comes to sustainability and eco-friendliness, rigid packaging boxes outweigh mylar packaging. 

Also Read:Custom Rigid Boxes: Everything You Need to Know

Mylar (Flexible) VS Rigid Packaging: Features and Applications 

In this section, we are going to discuss features and applications of mylar and rigid packaging. Here’s what you need to know. 

Mylar Packaging Features and Applications 

Some of the notable mylar packaging features and applications include:

Mylar Packaging Features

Moisture Resistance: Mylar packaging is best for storing food due to its moisture-resistant property. It prevents the food from becoming soggy, which ultimately leads to increased shelf life. 

Odor Resistance: Food items are vulnerable to odor, which can effectively be tackled by using Mylar packaging bags. 

Sealing Property: Mylar packaging for food can be sealed, which creates an airtight environment. This helps prevent food from being exploited and extends shelf life. 

Protection Against Light: The Quality of food items can deteriorate when exposed to direct light. However, the use of a mylar packaging bag for food storage is best for protection against light. 

Strength and Flexibility: Mylar packaging bags are made of robust material, offering more strength and durability, protecting against wear and tear. Moreover, the mylar packaging is available in various sizes and shapes, and can be easily molded in any form, giving it a flexible property. 

Easily Customizable: Mylar bags can be adjusted and customized with the company’s name, logo, color, and product information. 

Zipper Closure: Mylar packaging bags functionality can be enhanced by adding a zipper closure to keep the content inside and protected. 

UV Protection: Mylar packaging bags are highly resistant to UV rays due to their material and properties. 

Mylar Packaging Applications

As discussed earlier, mylar packaging bags are widely used for food storage due to their top-notch barrier properties against heat, air, light, and moisture. Some of the notable applications/uses of mylar packaging include:

Food Storage: Mylar bags for food storage, when used with oxygen absorbers, can preserve dry food items like pasta, beans, rice, lentils, and many more for 20-30 years. 

Document Preservation: Mylar packaging is widely used for preserving legal and personal documents to protect against fading and moisture. 

Camping and Hiking: Hikers and adventurers can use Mylar bags to protect their belongings, such as smartphones and other valuables. 

Emergency Supply: Mylar bags are also popularly used for storing emergency supplies such as medicines, food, and water. 

Industrial Use: Mylar packaging is used in various industries such as automotive, construction, and aerospace. 

Also Read: List of Best Foods to Store in Mylar Bags

Rigid Packaging Features and Applications

Here are some of the features and applications of rigid packaging boxes you need to know. 

Rigid Packaging Features

Unlike mylar packaging, rigid packaging constitutes an inflexible and firm structure made from corrugated cardboard, glass, or metal. Some of the notable features of rigid packaging boxes include:

Strength and Durability: Rigid packaging is known for its robust nature, durability, and sturdiness. These features are not only helpful in protecting the items from breaking and damage, but also prevent them from temperature, moisture, heat, and light. 

Versatility: Rigid packaging is not only for a particular category or niche, but is widely adopted by almost every business, including but not limited to food, electronics, clothing, bakery, cosmetics, health, and many more. 

Customization: Rigid packaging is not just a protective gear for the safety of products within. It is also a representation of brand identity. These rigid boxes can be customized in various shapes and sizes, along with branding elements such as logo, color, and slogan. 

Packaging Luxury and Premium Goods: Rigid boxes are widely popular for packaging luxury and premium products. In fact, the perceived value of luxury packaging i.e., rigid boxes, is quite high among consumers. Products like luxury watches, niche perfumes, and designer clothes are all displayed in rigid packaging boxes. 

Display on Retail Shelves: Displaying products on retail shelves means competing with hundreds of other products. However, with rigid packaging boxes, there is an extra edge over rival products to attract customers and force them to add to their carts. 

Speciality Packaging: Specialty packaging is something used by brands to promote their new line of products, and instigate people to save more and spend less, create brand identity as a new entrant. Speciality rigid packaging is also popular and seen around during the holiday season, such as Christmas and New Year. 

Electronics and Gifts: Electronics and gifts are widely adopted by brands offering gifts and electronics. The rigidity of rigid packaging provides a safe place to keep electronics from any damage. While the gifts are packaged to display the value and premiumness of the gifts. It is particularly useful in increasing sales during holidays and other occasions.

Also Read:Why Are Rigid Boxes Preferred for Gift Packaging

Flexible (Mylar) Packaging Vs Rigid Packaging: Pros And Cons

So far, we have discussed briefly about mylar packaging, also known as flexible packaging and rigid packaging, functions, and applications. It is now time to reveal the pros and cons of flexible packaging and rigid packaging side by side to help you decide which one is better for your business. Here’s everything you need to know. 

Flexible (Mylar) Packaging Pros and Cons 

Some of the pros and cons of Mylar packaging are:

Pros of Mylar Packaging

Prevent Odor and Moisture: Mylar bags for food storage are ideal due to their extensive barrier properties that help in extending shelf life. For instance, it prevents odor formation and moisture from entering the bag, resulting in less spoilage and more protection. 

Durable and Flexible: Mylar bags are known for durability and flexibility. No matter how hard you try, it isn’t possible to tear or puncture the bags without some extraordinary force. Flexible packaging is used for various purposes apart from storing food, such as storing documents and electronic devices. 

Affordable Option for Startups: Custom packaging for small businesses and startups is hard to afford when the funds are tight; however, not in the case of Mylar bags, as they are a cost-effective option for every size of business. 

Long-term Food Storage: Dried food items such as flour, grains, beans, and lentils are going to stay on shelves for God knows how long. Preserve your food items for a longer period without worrying, as custom mylar packaging bags help in protecting the food from exposure to air, moisture, heat, and light. 

Lightweight: Mylar bags for food storage are lightweight, which makes the storage convenient and transportation easy. 

Cons of Mylar Packaging:

Sustainability and Eco-friendliness: Mylar bags are not sustainable for the environment as they are not recyclable or biodegradable. 

Visual Appeal: Compared to rigid or other forms of packaging, mylar packaging is not ideal in terms of aesthetics and visual appeal. 

Handling: Mylar packaging needs to be handled with care because if they are not sealed properly, it may spill the food, resulting in a huge financial loss. 

Also Read: Best Custom Mylar Bag Companies

Rigid Packaging Pros and Cons 

Rigid packaging has been a popular choice for brands and small businesses to attract customers. However, with a lot of pros and a few cons, it is better to know every aspect before deciding on which one to choose for your business. 

Pros of Rigid Packaging:

Protection at its Best: Rigid packaging is quite popular for its sturdiness and rigidity. This means they are highly capable of protecting fragile and delicate items. 

Eco-friendliness and Sustainability: Contrary to the rigid packaging, rigid boxes are sustainable, eco-friendly, recyclable, and reusable. 

Provide an Easy Unboxing Experience: Rigid boxes are adopted by small businesses and big brands to present their products in a premium style. With an easy unboxing experience, the chances of gaining more traction, attracting more sales, and boosting brand identity become multifold. 

Easy Customization: Custom packaging for small businesses helps in boosting sales, driving revenue, and creating brand identity. Rigid packaging boxes are easily customizable with branding elements such as the company’s logo, unique colors, slogan, and much more. 

Easy to Handle: Rigid packaging is all about convenience and sustainability. The overall making of rigid packaging is such that it can be easily handled without any extra effort. 

Cons of Rigid Packaging 

High Cost: Due to the premium nature of rigid boxes, the cost of producing custom packaging rigid boxes is quite high as compared to flexible or any other type of packaging. 

Bulkiness: Due to rigidity and sturdiness, rigid packaging boxes are bulkier than flexible packaging. The boxes can’t be folded, therefore, the shipping and storage costs are quite high. 

Less Versatility: Rigid packaging boxes are less versatile, meaning they cannot be molded, folded, or spread, resulting in more space and storage. 

Also Read: Best Wholesale Supplier of Custom Rigid Packaging

Types and Uses of Rigid Packaging Vs Mylar Packaging 

Custom rigid boxes are a popular packaging solution due to their sturdy, luxurious appearance and ability to protect products during shipping and handling. They come in various designs and styles, depending on the product they are meant to house. Below are the most common types of custom rigid boxes:

Rigid Packaging Types and Uses 

Two-Piece Rigid Boxes (Set-Up Boxes)

These are traditional rigid boxes with a lid and a base. They are used for packaging high-end gift boxes, premium product packaging (e.g., jewelry, electronics). Two-piece rigid box features a high-end, customizable, and sturdy material with printing and embossing capabilities.

Magnetic Closure Rigid Boxes

These boxes have a magnetic flap or closure, which secures the lid without the need for a clasp or ribbon. They are widely used for packaging premium gifts, subscription boxes, and luxury packaging. Magnetic closure rigid boxes feature sleek and modern, easy-to-open and close, adding an element of surprise and sophistication.

Slipcase Rigid Boxes

A slipcase box consists of a sleeve (slipcase) that fits over a rigid inner tray. Used commonly for book packaging, media packaging (e.g., DVDs, Blu-Rays), and high-end product sets.

They can be used to store multiple items, offering a minimalist but elegant design.

Book Style Rigid Boxes

These are boxes that open like a book, often with a hinged lid and a magnetic or clasp closure. Commonly used for packing luxury books, high-end gift packaging, and designer products. The book style rigid boxes feature a hinged lid, often with a soft-touch finish, and can include compartments or dividers.

Drawer Rigid Boxes

A drawer-style box slides open like a drawer, often with a pull tab or ribbon to make it easier to open. Commonly used for packaging cosmetics, skincare products, and tech accessories. Drawer rigid boxes are easy to access, modern, and come with a stylish design.

Collapsible Rigid Boxes

Description: These are rigid boxes designed to be foldable for easier storage and shipping. Once assembled, they are sturdy and maintain their shape. They are widely used for seasonal promotions, high-volume products, and retail packaging. Collapsible rigid boxes are compact, cost-effective, and offer a premium look.

Round Rigid Boxes

Instead of traditional square or rectangular shapes, these boxes have a cylindrical or round shape. They are commonly used for hat boxes, product packaging, perfumes, and cosmetics. Round rigid boxes have a unique and distinctive appearance, a luxurious feel, and add an element of surprise.

Luxury Rigid Boxes with Inserts

These boxes often come with custom foam, fabric, or cardboard inserts to hold the product securely in place. Widely popular for watches, electronics, high-end jewelry, and custom gift sets. The inserts can be customized to fit different products, ensuring they are not damaged in transit.

Hinged Rigid Boxes

These boxes have a hinge that connects the lid to the base. It’s a very durable and secure option, typically used for high-end products. Ideal for packaging luxury watches, high-end electronics, and gifts. Hinged rigid boxes are heavy-duty, with optional magnetic or clasp closures for added security.

Flip Top Rigid Boxes

A box that opens by flipping the top open, typically secured with a magnet, clasp, or ribbon. Ideally used for gift sets, cosmetics, and apparel. Flip-top rigid boxes feature an Elegant opening mechanism, are easy to use, and often include foam or custom dividers.

Display Rigid Boxes

These boxes are designed to be displayed on shelves and often have clear plastic windows or open fronts to showcase the product. Ideal for retail packaging, collectible items, and small electronics. Display rigid boxes feature customizable windows, usually with a flat base to allow stacking or showcasing.

Custom Shaped Rigid Boxes

These are rigid boxes made in unique or custom shapes to fit a specific product. Common uses include specialized products or promotional items packaging, where branding requires a unique design. Customized rigid packaging can be molded or cut into nearly any shape, making it eye-catching and memorable.

Mylar Packaging Types and Uses 

Stand-Up Pouches 

These Mylar bags have a gusseted bottom, allowing them to stand upright on retail shelves. They often come with a resealable zipper and are commonly used for food and non-food products. Commonly used for storing snacks, pet food, coffee, tea, spices, and supplements.

Stand-up pouches, mylar packaging are durable, resealable, and can include a tear notch or spout for easy pouring. Great for showcasing products on shelves.

Vacuum Sealed Mylar Bags

These bags are used in vacuum sealing, where the air is removed from the bag to increase the shelf life of products by minimizing exposure to oxygen, which can cause spoilage. Ideal for long-term food storage such as freeze-dried meals, emergency supplies, preservation of dried goods, and electronic components. Vacuum-sealed mylar bags have an airtight seal, increased durability, and excellent barrier protection against moisture, air, and light.

Mylar Foil Bags

A type of Mylar bag that is laminated with a thin layer of aluminum foil, providing enhanced protection from light, moisture, and oxygen. These bags are ideal for storing pharmaceuticals, food storage, and products sensitive to UV light or air (e.g., coffee, dried fruits, snacks).

Mylar foil bags feature a shiny or metallic finish and strong barrier properties.. Great for items that need to be shielded from light or kept fresh for extended periods.

Mylar Tubes

Mylar tubes are cylindrical packages made from Mylar film and are often used for packaging small items or products like rolled-up posters, herbs, or small gifts. Ideal for packaging art and craft supplies, collectibles, small electronics, and food items like cookies or candies. These bags have a tight seal, often with screw-on or snap-on caps for easy access.

Mylar Pouches with Zippers

Description: These pouches are designed with a resealable zipper for easy access and closure. They’re widely used in the food and consumer goods industry, such as packaging snacks, pet food, herbs, and candies. Mylar pouches with zippers are reusable, easy-to-open, airtight, and moisture-resistant, available in a variety of sizes.

Mylar Packaging with Windows

Mylar bags or pouches that have a clear plastic window are designed to give consumers a glimpse of the product inside. They are widely popular for storing snacks, baked goods, pet treats, and other retail items. These flexible packaging with windows provide product visibility while maintaining the protective properties of Mylar. 

Mylar Sachets

Small, single-use Mylar packets, often used for products like silica gel or small quantities of items like spices or powders. It is ideal for storing electronics, shoes, and leather goods.

Mylar Pouches with Spouts

These are Mylar pouches that come with a built-in spout, often used for liquids or semi-liquids, allowing for easy pouring or dispensing. Ideal for storing sauces, beverages, juices, soups, and other liquid-based products. These flexible packaging pouches with sprouts have a resealable spout, easy-to-pour, space-efficient packaging.

Mylar Stand-Up Pouches with Gussets

Similar to regular stand-up pouches but with gussets on both sides, these pouches are designed to hold bulkier or larger items, expanding to allow for more capacity. Best for storing dry goods, snacks, pet food, and other bulk products. These stand-up pouches have a huge capacity, sturdy base for upright display, and are often resealable.

Factors to Consider when Choosing a Packaging Supplier

Finding the best packaging supplier near me gives a lot of options. However, choosing the best one isn’t child’s play. With a lot of custom packaging suppliers for small businesses, choosing the right one requires some analysis. Here’s a brief overview of things you need to consider when choosing a packaging supplier in your area. 

Mylar VS Rigid: Which One is Best for Your Business?

Choosing between mylar packaging and rigid packaging depends on the nature of your business and the type of product you want to store. If you are running a food business, the preferred voice should be Mylar packaging. 

However, when it comes to high-end luxury products that are sensitive and fragile, rigid packaging is the best one to choose from.

In case you need assistance of any type on which packaging is best for you, simply get in touch with the IMH Packaging sales team at +1-312-517-0995