Description

More Volume Without Losing Barrier Performance

A gusset, a folded panel built into the side or bottom of a bag, allows a mylar bag to hold significantly more product than a flat pouch of the same width, without sacrificing the strong barrier protection that makes mylar a preferred material in the first place. Custom gusset mylar bags from Betec Packaging are built for brands that need that extra capacity, whether that’s a larger coffee bag size or a bulk specialty food product.

How Gusseted Construction Adds Real Capacity

The gusset expands outward as the bag is filled, effectively widening the bag’s usable interior volume well beyond what a simple flat pouch could hold at the same overall dimensions. Side gussets add width along the vertical edges, while bottom gussets create a flat, stable base similar to a stand-up pouch, and the right choice generally depends on whether shelf stability or maximum fill volume matters more for a given product.

Materials for Gusseted Mylar Construction

• Metallized mylar film, the standard high-barrier material for gusseted bags
• Matte mylar, offering a premium, low-glare finish
• Kraft-look mylar laminate, combining a natural visual aesthetic with mylar’s barrier performance

Gusset Style Options

Side-gusset bags expand along the sides, increasing width without changing the bag’s overall footprint, well suited to bulkier or coarser products. Bottom-gusset bags create a flat, freestanding base, functioning similarly to a stand-up pouch while offering the added barrier strength of mylar construction.

Personalize Your Gusset Mylar Bags

CMYK printing covers the bag’s full front and back panels, and gusseted designs often extend branding onto the side panel as well, giving brands additional space for ingredient information, certifications, or secondary branding elements. PMS matching keeps colors consistent across every production run, which matters for brands selling multiple product sizes under one visual identity.

Why Choose Betec Packaging?

Betec Packaging engineers gusset placement and sizing around your product’s actual volume and fill weight, rather than defaulting to one standard gusset depth regardless of what’s going inside. Every order includes free design support and a digital proof before production, and zipper closures and degassing valves can both be added to gusseted mylar bags as needed. Our production scales from smaller specialty batches to full bulk production runs.

Get a free quote and let Betec Packaging help your product get the extra capacity it needs without losing an ounce of protection.