Making film bags yourself is easier than you think. With tubular film on a roll, a suitable film sealing device and a few simple steps, you can produce bags in exactly the size you need within minutes – without expensive bespoke confectioning and without holding stock for 20 standard sizes. This detailed guide shows you step by step which material you need, which thicknesses suit which application, what the correct sealing settings look like and when in-house production pays off – and when ready-made confectioning or a bespoke order makes more sense.
Table of contents
- What is a film bag?
- Why make film bags yourself?
- Material: tubular film in detail
- Which film thickness (microns) for which application?
- Tools & sealing devices compared
- Guide in 6 steps
- Sealing settings per thickness
- Making food-grade film bags yourself
- Ready-made film bags or bespoke order?
- Common mistakes and solutions
- Sustainability & recycling
- Frequently asked questions
What is a film bag?
Film bags are packaging bags made from thin, flexible plastic film – usually from LDPE (low-density polyethylene). They are transparent, soft, easy to print and fully recyclable. Common synonyms are PE bags, poly bags or simply “plastic bags” (see also our plastic bag glossary). Film bags can be supplied ready-made or you can make them yourself from tubular film on a roll.
Unlike stand-up pouches or block bottom bags, classic film bags have no standing base – they lie flat and are the simplest, most economical form of plastic packaging.
Why make film bags yourself?
- Custom dimensions – a perfect fit for your product, without standard sizing
- Reduce stock – one roll of tubular film covers several bag sizes
- Cost savings for large in-house quantities compared with ready-made goods
- Just-in-time – make only what you currently need
- Test packaging – quickly make prototypes for new products yourself
- Special sizes – possible even when a bespoke order from the manufacturer is not economical
Material: tubular film in detail
The basis of any in-house production is PE tubular film: a seamless plastic film in tube form, already closed on two sides. You only need to seal the top and bottom. Read more about the material in our PE tubular film guide.
Available material variants:
- LDPE (standard) – flexible, tear-resistant, transparent, very easy to print
- LDPE food-grade – certified to EU 10/2011 for direct food contact → food-grade tubular film
- LDPE extra strong – for heavy or sharp-edged contents → extra strong tubular film
- Recycled LDPE (GRS) – from 100% post-consumer material, identical function with a much better carbon footprint → sustainable films
- Cut to size – tubular film in your desired width → tubular film cut to size
Which film thickness (microns) for which application?
| Thickness (microns) | Recommended application | Properties |
|---|---|---|
| 30–50 microns | Light contents: fabric, paper, small parts, loose bulk goods | very thin, easily torn, economical to use |
| 50–80 microns | Standard application: food, shipping goods, clothing | good compromise between strength and cost |
| 80–120 microns | Medium-weight contents: tools, screws, spare parts | noticeably firmer, good load capacity |
| 120–200 microns | Heavy & sharp-edged contents: industry, metal parts | extra tear-resistant, puncture-resistant |
| 200+ microns | Highest stress, liners for big bags | bespoke order, very robust |
Tools & sealing devices compared
You need the following tools:
- Tubular film in a suitable width and thickness
- Film sealing device – impulse sealer or constant-heat bar sealer
- Cutter, scissors or film cutter for a clean cut
- Ruler or stop for precise and repeatable dimensions
- Optional: label printer for content details / best-before date
Sealing devices compared:
- Impulse sealer (£50–250) – heats up only briefly when pressed. Ideal for hobby, small trade and occasional production. Seams 100–600 mm.
- Bar sealer (£250–1,500) – constantly heated, very fast. Standard for regular production. Seams up to 1,000 mm and more.
- Continuous band sealer (from £1,000) – continuous seam. For large series.
- Vacuum sealer – combines sealing with air extraction. For vacuum packaging.
Guide in 6 steps
- Set the dimensions: bag width = tubular film width. Bag height = desired content height + approx. 4–6 cm sealing allowance at the top.
- Unroll the film: unroll the tubular film to the desired length, mark it precisely with a ruler.
- Cutting: cut precisely with a cutter or scissors.
- Seal the bottom seam: place one edge in the sealing device, seal for approx. 3–5 seconds (depending on material thickness). The seam must be continuous, smooth and free of bubbles.
- Filling: turn the bag over and fill it from the top. Leave at least 3 cm clearance from the top edge.
- Seal the top edge: clamp the filled bag and seal it. Your film bag is ready.
Sealing settings per thickness
| Film thickness | Sealing time (impulse sealer) | Sealing time (bar sealer) |
|---|---|---|
| 30–50 microns | 1.5–2.5 seconds | Level 1–2 |
| 60–80 microns | 2.5–3.5 seconds | Level 2–3 |
| 100–120 microns | 3.5–5 seconds | Level 3–4 |
| 150–200 microns | 5–7 seconds | Level 4–5 |
Note: the values are guidelines. Before each production run, test 2–3 trial seams and check the tear resistance.
Making food-grade film bags yourself
For direct contact with food the rule is: use only food-grade certified tubular film (EU 10/2011). Available at Elke Plastic as food-grade tubular film. We send declarations of conformity on request. Typical applications: bakery liners, take-away, vacuum preparation, direct sale at the farm shop.
Ready-made film bags or bespoke order?
In-house production pays off above all when you need changing dimensions or flexibly make smaller quantities yourself. Ready-made bags make sense for stable standard sizes – no sealing effort, fewer sources of error. Bespoke orders directly from the manufacturer pay off from larger quantities, for very specific dimensions, for custom printing or when you want to save the effort of in-house production.
- Ready-made flat bags – standard confectioning in many sizes
- Ziplock bags – resealable
- Stand-up pouches – with standing function
- Bespoke orders – from a larger quantity, with logo
Common mistakes and solutions
- Seam tears: sealing time too short – increase it. Or film too cold – let the device warm up.
- Film burns through: sealing time too long – reduce it. Or thickness too low for the setting.
- Bubbles in the seam: film dirty or damp – keep it clean.
- Uneven seam: contact pressure not even – insert the film cleanly.
- Bag too small: factor in the sealing allowance (4–6 cm).
Sustainability & recycling
LDPE film is recyclable as a single material and belongs in the recycling collection. For environmentally conscious applications there is tubular film made from 100% recycled LDPE (GRS-certified) – functionally identical, with a much better carbon footprint. More on this in our sustainable packaging. In-house production plus recycled film is one of the most efficient packaging strategies of all.
Material overview and glossary in our packaging glossary.
Frequently asked questions
Which sealing device is best to start with?
For hobby and small trade use an impulse sealer is sufficient (£50–200). Make sure the sealing width is adequate (at least 30 cm). For regular production a bar sealer is recommended – faster and more durable.
What widths are available for tubular film?
Typically 100–800 mm. Special sizes on request. The tubular film width corresponds to the later bag width. → tubular film cut to size.
How safe are self-sealed film bags?
With a correctly set sealing device the seams are practically just as tear-resistant as machine-confectioned bags. Always test sample bags before large series (tear test with contents).
Can I also buy tubular film as flat bags?
Yes – on request we supply tubular film cut to size or as ready-made flat bags in many standard sizes.
Which film thickness for food?
For dry food 50–80 microns is sufficient. For damp or greasy contents 80–120 microns is better. Always use food-grade certified film.
How long does a seal last?
A cleanly sealed LDPE seam lasts practically indefinitely. It does not age any faster than the film itself – so many years in dry storage.
Can I also seal HDPE or PP?
HDPE yes, with adjusted sealing time (shorter, higher melting heat). PP/OPP becomes more difficult because the material reacts more brittly. Standard sealing devices are designed primarily for LDPE.
What does in-house production cost vs. ready-made confectioning?
For small quantities (under 1,000 bags/month) ready-made confectioning is usually cheaper per unit. From medium quantities or with frequently changing dimensions, in-house production pays off strongly.
How do you store tubular film correctly?
Dry, dark, at room temperature. Avoid direct sunlight and UV radiation – otherwise LDPE can become brittle over months. In its original packaging the film stays stable for many years.
Can I also get tubular film printed with a logo?
Yes – as part of bespoke orders we print tubular film with your logo or branding. Lead time and minimum quantity on request.
Straight to the tubular film range: → Packaging films · Ready-made bags: → Packaging bags · Bespoke order: → Request a made-to-measure order