Bubble Zip-Lock Poly-Bags: A Closer Look

12/29/16

Bubble zip-lock poly-bags are a protective packaging option that also provides an upscale look to the packaged item.

How they are made?

1. The bag without the bubble sheet inserts are first made. Two different rolls of center-folded material are machined one on top of the other to create a “bag shell”. The “bag shell” has 4 layers of material sealed on both sides, zip-locked at the top and open at the bottom. The 4 layers create three openings at the bottom. One opening between one layer of centerfold. Another layer between the other layer of centerfold. The third opening between the layers of centerfold. This third opening will be the inside usable space for the finished bag.
2. Custom 3/16″ bubble sized bubble sheets are made separately. The sheets are typically 3/8″ smaller than the bags size to allow the bubble sheets to slide into the bottom of the bag between layers of the centerfold on each side of the bag.
3.  The bubble sheets are hand loaded into the bottom of the bags between each layer of centerfold.  Each bag requires two bubble sheets. The sheets are fully encapsulated by the surrounding poly and “float” inside the walls of the bag. The sheets are slightly smaller than the bag itself so the sheet movement once the bags are made is minimal.
4.  After the sheets are loaded, the bottom of the bag is hand sealed. The hand loading of the bubble sheets and the bottom sealing are done by local handicap workshops.
5.  Once sealed, the bag is finished and loaded into boxes for shipment (typically 50 per case). The finished bags are loaded by the end user thru the zipper.

Restrictions for Bubble Zips

1.  Smallest we can make is a 4×4.  Largest is 30×30.
2.  One side print only (in certain circumstances, we can print a second side BUT the second side cannot have registered print: random print only).
3.  Tolerances for bag sizes and bubble sheets size within the bags is +/-1/4″.
4.  Lead-times are typically 5 to 7 weeks depending on the volume and size. The longer lead-time is a function of needing two separate components to make the bags (sheets and bags) and the manual process to make each individual bag.
5.  The bags are made with a “skirt” at the bottom.  The skirt is typically 1.25″ long and serves as the bottom sealing area for the bags once the sheets are loaded.

Options Available

1.  6 stock sizes are available. Each stock bag is printed “reusable: do not discard”. The stock sizes are 4×6, 6×8, 8×10, 8×12, 10×12 & 12×12. Each is packed 50 per case.
2.   Different bubble sizes are potentially available upon request. The typical bag has a 3/16″ bubbles.
3.   Most bubble ziplocks are made in 003 mil LDPE. Can make in 002, 0025, 003, or 0035 mil.
4.   Can print up to 8 colors on 1 side of the bag.

Samples of previously made bubble bags are available upon request. We can also hand make custom samples for sizing for your specific purposes if desired.

Thanks for reading!