Finding the Right Tape for Heavy-Duty Boxes Springing Back Open

When a specialty powder manufacturer came to Consolidated Printing Supplies (CPS) with a critical packaging issue, our team went beyond off-the-shelf tape solutions and engineered the right adhesive match for their unique needs.

📦 The Problem: Boxes That Wouldn’t Stay Closed

This customer produces a dense, industrial-grade powder that’s packaged in 200 lb test corrugated boxes — significantly stronger and more rigid than standard 32 ECT or 44 lb test cartons.

While the boxes were durable enough to hold the product’s weight, they had one big flaw:

The box flaps kept springing open and pulling the packing tape off.

The thickness and memory of the corrugated material caused the boxes to fight back against closure, especially during colder temperatures or rough handling. Standard packing tape simply couldn’t maintain adhesion, and boxes were reopening in transit, causing product loss and shipping delays.

🧪 The CPS Solution: Matching the Right Hot Melt Adhesive

At CPS, we don't just sell tape — we engineer solutions.

After evaluating the customer’s box construction, storage environment, and application process, we identified a specialized hot melt packaging tape with:

• High initial tack to bond immediately upon application

• Strong holding power for thick, high-memory corrugated flaps

• Temperature tolerance to maintain adhesion in fluctuating warehouse or shipping conditions

• Balanced elongation to absorb box flex without peeling

The result? A tape that actually worked with the box, not against it.

🏆 The Outcome: Secure Seals and Smoother Shipping

Since switching to the CPS-recommended hot melt tape, the customer reported:

• 100% box integrity in transit

• Zero unintentional openings across multiple production runs

• Improved production speed due to reduced resealing

• Lower material waste and damage claims

Why the Right Tape Matters for Heavy-Duty Boxes

Not all packing tapes are created equal — especially when dealing with high-weight products and stiff corrugated board. CPS specializes in helping manufacturers:

• Match tape adhesive to box strength and memory

• Improve seal integrity under load

• Eliminate tape failure in 200 lb test boxes, double-wall cartons, and other challenging materials

📞 Need Help with a Tough Packaging Challenge?

If you’re fighting tape failure on thick or specialty boxes, don’t guess. Let CPS help you engineer a solution that works — with the right adhesive, tape width, and application method for your operation.

👉 Contact us today for a sample or consultation.