Flexo vs. Digital Printing for Custom Mylar Bags
Written by Lia Thompson, packaging specialist at Creative Labz. Last updated October 3, 2026.
When a brand is ready for fully custom Mylar bags, the first decision is the printing method. The two most common options are flexographic (flexo) and digital printing. Each one changes your minimum order, setup cost, lead time, and how the finished bag looks. Picking the wrong one can mean paying for 10,000 bags when you needed 1,000, or getting a short run that costs too much per bag.
This guide explains how flexo and digital printing work, how they compare, and how to choose the right one for your brand.
How Flexo Printing Works
Flexographic printing uses flexible printing plates, one for each ink color, mounted on rotating cylinders. Film runs through the press at high speed while each plate prints its color in turn. The printed film is then laminated and converted into bags.
- Strengths: very low cost per bag at high volumes, fast press speeds, and consistent color across large runs.
- Tradeoffs: each design needs its own set of plates, which adds setup cost and lead time. Minimum orders are typically large.
How Digital Printing Works
Digital printing sends your artwork straight from a file to the press, with no plates. That makes setup fast and inexpensive.
- Strengths: low minimums, no plate costs, quick turnaround, and easy changes between designs or strains.
- Tradeoffs: a higher cost per bag than flexo at large volumes.
Flexo vs. Digital at a Glance
| Flexo | Digital | |
|---|---|---|
| Setup | Plates for each color and design | No plates |
| Minimum order | Large | Small |
| Cost per bag | Lowest at high volume | Higher at high volume, competitive at low volume |
| Design changes | New plates for each change | Easy |
| Best for | One or a few designs in large quantities | Many strains or designs in smaller quantities |
Which Printing Method Is Right for You?
Choose flexo if you sell a few core products in steady, high volume and your design won't change often. The setup cost spreads across many bags.
Choose digital if you're launching, run many strains, release limited drops, or want to test designs before committing.
Choose neither yet if you're still finding your volume. Stock packaging plus custom labels gets you a branded look with almost no minimum.
The Stock-Bag Alternative
Before investing in custom printing, many brands start with ready-made or plain Mylar bags and add their branding with custom vinyl stickers sized for Mylar bags. It's a low-risk way to launch and learn what sells. Our guide to pre-printed vs. custom cannabis packaging compares the options in more detail.
Tips for Any Custom Print Run
- Ask for a proof and check colors, text, and required warnings before approving.
- Leave room for compliance labels that may change, like batch numbers and test results.
- Plan for the heat seal area above the zipper so artwork doesn't get cut off.
- Use a size chart. See our Mylar bag sizes and types guide to pick the right bag before you design.
Frequently Asked Questions
Is flexo printing better quality than digital?
Both can produce sharp, professional results. Flexo excels at consistent color over long runs. Digital handles complex artwork and many design variations easily.
Why are flexo minimums so high?
Every design needs its own printing plates, and the press setup takes time. Those fixed costs only make sense when spread across a large number of bags.
Can I switch from digital to flexo later?
Yes. Many brands start with digital or stock bags and move to flexo once a product's volume is steady.
Start With Stock, Grow Into Custom
Creative Labz carries Mylar bags in ready-made designs and plain finishes, plus custom stickers, so you can launch with a branded look today.