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How to Make Reusable Sandwich Bags and Snack Bags

Reduce waste and pack lunches sustainably with DIY reusable sandwich and snack bags—easy, affordable, and customizable for everyone.

By Sneha Tete, Integrated MA, Certified Relationship Coach

Created on Jun 10, 2025

Reduce waste and pack lunches sustainably with DIY reusable sandwich and snack bags—easy, affordable, and customizable for everyone.

Disposable plastic sandwich and snack bags are a major source of unnecessary household waste. Making your own reusable bags is an easy, satisfying project that benefits both your wallet and the environment. This step-by-step guide will show you how to sew custom, washable bags that are perfect for lunches, snacks, travel, and more.

Why Choose Reusable Bags?

Eco-Friendly: Reduce plastic waste sent to landfills and oceans.
Cost-Effective: Save money by reusing instead of buying disposable bags.
Customizable: Choose your own fun fabrics and sizes to fit any need.
Food-Safe: Select materials that are non-toxic and safe for direct contact with food.

Supplies You’ll Need

Before you begin, gather the materials below. Sizes and specific details are adaptable based on your needs (e.g., for sandwiches or snacks).

Cotton fabric: Washed and ironed, in patterns or colors of your choice, for the outside layer.
Food-safe vinyl (iron-on fusible vinyl): For waterproof, wipeable lining.
Thread: Coordinating or contrasting, high-quality sewing thread.
Hook & loop closure (Velcro): Sew-on, not adhesive-backed.
Scissors: Fabric scissors for clean cuts.
Curved object: (e.g., glass or bowl, for rounding corners).
Pins or clips: To hold pieces together while sewing.
Sewing machine (or needle for hand-sewing, though machine is faster).
Iron: For fusing vinyl and pressing fabric.
Paper backing: Save backing from fusible vinyl application.

Preparation and Fabric Selection

Choose 100% cotton fabric for the outside to ensure breathability and vibrant color. Wash and iron your cotton before cutting to avoid shrinkage after your bags are made. For the bag’s lining, an iron-on fusible vinyl is preferred because it creates a waterproof barrier and is food-safe—ensure your product is BPA- and phthalate-free.

Common dimensions for finished bags:

Sandwich bag: 7″ x 7″ finished size (cut fabric pieces to 7.5″ x 7.5″ to allow for seam allowance).
Snack bag: 6″ x 4″ finished size (cut fabric to 6.5″ x 4.5″).

Adjust sizes to suit your lifestyle—larger sandwiches, wraps, or smaller snack portions.

Step One: Cut Fabric and Vinyl

Cut two rectangles for each bag you plan to make: one outer cotton piece and one piece of iron-on vinyl (if the vinyl is separate from the liner). Iron-on vinyl should be trimmed 1/4 inch smaller on all sides than your fabric to ensure clean, sealed seams.

For each bag: cut one cotton rectangle and one matching vinyl rectangle per side (front and back).
Be sure to save one sheet of the vinyl’s paper backing—it will be useful in later steps and for bag maintenance.

Step Two: Fuse the Vinyl to the Fabric

Following the manufacturer’s directions for your brand of iron-on vinyl:

Peel the vinyl from its paper backing.
Lay the vinyl adhesive side-down onto the right side (printed side) of the cotton fabric.
Put the backing paper shiny-side-down over the vinyl. Use a hot, dry iron (no steam) to press for 8 seconds.
Flip the fabric so the wrong side faces up; press again for 8 seconds. This clearly fuses the vinyl.
Repeat with each piece that requires a vinyl lining.

Allow the vinyl to cool completely before handling. The vinyl and fabric may feel somewhat stiff, which is intended for durability and easy cleaning.

Step Three: Round the Corners

For a smooth and professional finish, round one set of corners on each fabric strip (one short edge). Use a drinking glass, jar lid, or similar round object as a template.

Trace curved edges onto the corners with tailor’s chalk or a disappearing fabric marker.
Cut along the guidelines to shape the corners smoothly.

Step Four: Arrange and Pin

With the right sides together (the sides with the vinyl), align the fabric pieces. Pin or use clips to secure very close to the raw edges—this is important as visible pinholes may affect waterproofing. Keep pinholes within the seam allowance (1/4 inch from the edge).

Step Five: Stitch the Perimeter

Using a 1/4 inch seam allowance, sew around the perimeter of the fabric, leaving about a 2-3 inch opening on the straight edge (not the curved edge) for turning the bag right side out.
Backstitch at the beginning and end for durability.
Snip into but not through the seam allowance at any curved areas to reduce bulk and improve the finished appearance. Trim corners as needed.

Step Six: Turn the Bag and Press

Gently turn the bag right-side-out through the opening.
Use the saved vinyl paper backing as a buffer: Insert it into the bag before pressing to prevent the vinyl from sticking to your iron.
Finger-press the side seams, then carefully press with an iron if needed (using the paper backing as a barrier).
Fold the raw edges of the opening to the inside, aligning with the sewn seam; press or finger-crease in place.

Step Seven: Topstitch and Add Closure

Straight stitch or topstitch around the entire edge of the bag at 1/8 inch. This closes the opening and reinforces the bag for repeated use and washings.
Velcro or Hook & Loop: Sew strips of Velcro (or a similar closure) to the inside of the bag’s straight-edge flap and body, following your measured layout.

For sandwiches, use a 5-6 inch strip of Velcro for security.
For snacks, a shorter strip may suffice.

Tip: Avoid iron-on Velcro, as the adhesive is not typically food-safe or compatible with high temperatures. Sew-on Velcro ensures durability and food safety.

Customization Ideas

Fabric Choices: Mix and match patterns for different family members for easy identification.
Sizes: Make large bags for sandwiches or wraps, medium sizes for snacks, and minis for nuts or dried fruit.
Labels: Add name tags or fabric labels if desired.

Care & Maintenance

Cleaning: Wipe down after use for dry foods. For messier fillings, hand-wash or machine-wash on cold and air dry for best longevity.
Heat Safety: Do not microwave; these bags are meant only for cold or room temperature items.
Lifespan: With gentle care, your bags should last through many washings and daily use.

Eco-Friendly Impact

Switching to reusable sandwich and snack bags significantly reduces your household’s reliance on single-use plastics, eliminating waste after only one use. Each DIY bag you make can replace hundreds of disposable bags per year—especially useful for school lunches, office snacks, picnics, and travel.

Get children involved in choosing fabrics or helping with simple steps, encouraging lifelong awareness of sustainable choices and responsibility for the environment.

Troubleshooting & Tips

If your edges are bulky or difficult to turn out, trim seam allowances and round corners neatly before turning.
Pin within the seam allowance to minimize visible holes in the waterproof vinyl.
Test stitch with scrap vinyl-coated fabric to determine the best machine tension and needle for smooth sewing.

Table: Standard Sizes for DIY Sandwich & Snack Bags

Bag Type	Finished Size	Use
Sandwich Bag	7″ x 7″	Traditional sandwiches, wraps
Snack Bag	6″ x 4″	Crackers, dried fruit, veggie sticks
Mini Bag	4″ x 4″	Nuts, cookies, small treats

Frequently Asked Questions (FAQs)

Q: Are homemade sandwich bags safe for food?

A: Yes, provided you use food-safe, BPA- and phthalate-free vinyl or other certified food-safe liners. Always verify your source for safety certification.

Q: Can I put reusable bags in the dishwasher?

A: Some food-safe vinyls are dishwasher safe, but check your manufacturer’s guidelines. For best results, hand wash or use the gentle cycle and let the bags air dry.

Q: How long do these bags last?

A: With gentle care (no microwaving or hot-wash cycles), bags can last for hundreds of uses. Inspect regularly for wear and replace as needed.

Q: Will they keep food fresh as long as store-bought plastic bags?

A: DIY bags with an airtight Velcro closure will preserve freshness for most dry foods as well as disposable bags, but use a tighter seal or rigid container for items that spoil quickly or need to remain airtight for longer periods.

Q: Can I use other materials for the lining?

A: Yes. Ripstop nylon, oilcloth, and laminated cotton are popular alternatives, but always use materials with food-safe certifications for best safety and peace of mind.

Final Tips & Creative Uses

If gifting, present a set of bags tied with a ribbon—a thoughtful and useful eco-conscious present.
Other uses: organizing cords, make-up, or travel toiletries. These bags are versatile!

With this guide, you can make reusable sandwich and snack bags at home that are safe, attractive, and functional—perfect for creating a sustainable kitchen or sending kids off to school with fun, eco-friendly supplies.