Custom chip bags need more than great graphics. The right barrier film, seal structure, and headspace help protect chips from moisture, oxygen, oil, and handling damage—keeping snacks crisp and packaging shelf-ready.
Custom Chip Bags
Create custom chip bags for potato chips, tortilla chips, veggie chips, and other snacks. Choose your size, material, finish, and custom printing to create shelf-ready packaging that fits your product and brand
From 100 Units
Sustainable Options
Instant Quotes
3D Design Preview
Protect Crunch, Show Flavor
We tailor each bag to your product, whether you’re packing potato chips, tortilla chips, kettle chips, or other snacks. Size, material, seals, and filling-line requirements are confirmed before production.
Chip Moments
Thin Potato Chips
Protect delicate slices with credible headspace and fill
Kettle-Cut Chips
Keep irregular edges away from back and cross-seals
Tortilla Chips
Give larger pieces room through filling and case packing
Puffed Snacks
Balance bulky volume with a readable front panel
Veggie Chips
Confirm oil, color, and light exposure during setup
Mixed Snack Lines
Keep flavor systems consistent across changing product volumes
Material Options
Material Guide
Classic
OPP 1.6 milMETPET 0.5 milPE 2.8 mil
A durable, highly printable structure in matte, gloss, or soft touch. Strong oxygen, light, and aroma barrier for everyday products.
Recyclable
PE 2.0 milEVOH PE 1.6 milPE 1.6 mil
A mono-PE structure that stays compatible with PE recycling streams. The EVOH layer provides strong oxygen and aroma protection without giving up recyclability.
Compostable
Kraft Paper 70gsmPLA 2.0 mil
For brands going fully circular. Shorter shelf-life window than Classic or Recyclable, best for dry goods, lighter protection needs, and faster turnover.
Which Material Is Right for You
Not sure where to start? Think about what matters most for your product: protection, sustainability, or cost. The table below compares all four options.
PCR (post-consumer recycled) plastic is made from used consumer packaging, making it a more sustainable choice than virgin plastic.
Best for:CandySnacksBaked goods
Barrier(O2 / moisture / light):★★★★
Shelf life:Long▰▰▰▰
End of life:Standard waste
Finishes:Gloss / Matte / Soft Touch
Structure:OPP / METPET / PE
Classic
Classic
(High Barrier)
Recyclable
Compostable
Best for
CandySnacksBaked goods
CoffeePet foodSupplements
RefillsHome carePersonal care
TeaDried fruitSuperfood powders
Barrier(O₂ / moisture / light)
Shelf life
Long
Longest
Long
Shortest
End of life
Standard waste
Standard wasteStandard waste
PE recycling
PE recyclingIndustrial compost
Industrial compostFinishes
Gloss / Matte / Soft Touch
Gloss / Matte / Soft Touch
Gloss / Matte
Natural / White kraft
Structure
OPP / METPET / PE
OPP / PET / Foil / PE
MDOPE / EVOH / PE
Kraft / Clear PLA
Choose the Right Stick Pack Film for Barrier Protection
Choose a stick pack film based on your product’s sensitivity to oxygen, moisture, light, and aroma, as well as its target shelf life. Dylign Classic METPET-based structure provides dependable barrier performance for many dry products, while High Barrier stick pack film adds a foil layer for products that need stronger oxygen and moisture protection. For brands with sustainability goals, recyclable mono-PE/EVOH and compostable kraft/PLA structures are also available. Compare barrier performance, shelf-life needs, finish options, and material structure to choose the right custom stick pack packaging for your product.
Choose Your Structure by Crunch Risk
Everyday Retail
Everyday potato and tortilla chips: balanced barrier and print range, with multilayer disposal.
Use Classic (Standard)
Durability:★★★★
Structure:OPP / METPET / PE
Oil-Rich Holds
Oily or light-sensitive chips: foil-supported protection with higher material complexity.
Use Classic (High Barrier)
Durability:★★★★★
Structure:OPP / PET / Foil / PE
Recycle-Led Lines
Dry snack lines prioritizing mono-PE: strong barrier, while local recycling access needs confirmation.
Use Recyclable
Durability:★★★
Structure:Matte PE / EVOH / PE
Fast Craft Runs
Fast-turn dry chips: kraft-led appearance with lighter protection and industrial composting access to confirm.
Use Compostable
Durability:★★
Structure:Kraft / Clear PLA
Add-ons
Add a tear notch for easy opening in our 3D Design Tool.
Tear Notch
Finishing Effects
Premium surface treatments to make your design stand out, all in our 3D Design Tool.
Window
Spot UV
Hot Foil
Metallic Effect
How It Works?
1
Design in 3D
Customize your packaging and see your design come to life.
2
See Your Landed Cost
View your total landed cost instantly, with no hidden fees.
3
Approve Every Detail
Review your proof and sign off before production.
4
Order a Sample
Check your packaging in person before full production.
5
Place Your Order
Confirm your order and let us handle production and delivery.
Our Commitment
24h Review
Once your design is ready in our 3D tool or uploaded, you get confirmation within 24 hours.
7d Sample
Your production-press sample is made in 7 business days and rushed to your door.
12d Production
Once approved, your bulk order is produced in 12 business days, then ships at the speed you choose.
From Proof to Pouch in 15 Days
Not ready to commit to a bulk run yet? Before tooling, volume pricing, and a full production schedule, one sample lets you confirm print, structure, and how the product actually sits inside.
DAY 1–7
Sample production
Your approved proof moves into production.
DAY 8
QC & Sample photography
10 photos delivered around Day 10, ready for listings, ads, and AI mockups.
DAY 9–15
Express delivery
Your sample arrives by express courier.
Got questions? We've got answers.
How much headspace should a chip bag have?
There is no single headspace ratio that works for every chip. Start with the actual product volume, target net weight, chip size, breakage sensitivity, and filling process. Dylign lets you customize the bag dimensions around the filled product, and we recommend testing the final size with your actual chips before bulk production.
What material should I choose to keep chips crisp?
The right structure depends on what your chips need protection from, especially moisture, oxygen, oil, light, and aroma loss. Dylign offers different barrier and sustainability options so you can compare protection, appearance, and end-of-life goals. Oil-rich or moisture-sensitive snacks may require a higher-barrier structure, with the final specification confirmed before production.
How do I choose the right chip bag size?
Do not size a chip bag by ounces alone. Two snacks with the same net weight can have very different filled volumes. Use your actual chips, target weight, required headspace, and seal areas to determine the width and length. With Dylign, you can customize the dimensions, preview the packaging in 3D, and order a production sample to check the filled appearance.
Can custom chip bags work with nitrogen flushing or my filling line?
Yes, as long as the packaging specification is matched to your filling setup. If your co-packer or line uses nitrogen flushing, confirm the required bag dimensions, headspace, seal areas, and material performance before production. Nitrogen flushing is part of the filling process, while the packaging structure must provide the barrier and seal performance needed for the finished pack.
Can custom chip bags use recyclable or PCR materials?
Eligible Dylign flexible packaging can be configured with recyclable or PCR options, depending on the format and required performance. Because chips can be sensitive to moisture, oxygen, and oil, the sustainability option still needs to meet the protection requirements of your product. Final recyclability and food-contact suitability depend on the complete packaging specification.
What is the minimum order quantity, and can I test a sample first?
Dylign orders start from 100 units per specification, making it easier to test a new flavor, size, or design before scaling. You can preview your packaging in 3D and review the landed price before ordering, then order a production sample to check the material, print, size, seals, and fit with your actual chips.
One sample can save you thousands
SAMPLE COST
$75
PRODUCTION ERROR
$7,000
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