The Role of Tape in Reducing Packaging Assembly Time

How Industrial Tapes Are Transforming Efficiency and Labor Costs in Modern Packaging

In today’s fast-paced manufacturing and logistics environment, time is money — quite literally. Packaging lines are under constant pressure to meet higher throughput targets without sacrificing quality or protection. Traditionally, mechanical fasteners such as staples, nails, screws, or strapping bands have been the go-to for securing packaging, especially in heavy-duty applications. However, industrial adhesive tapes are emerging as a faster, cleaner, and more cost-effective alternative that can dramatically reduce packaging assembly time and lower labor costs.

At New Edge, our expertise in high-performance tapes allows us to help manufacturers streamline packaging operations while improving consistency and reliability.

Choosing the right tape can cut packaging costs more than ever

1. Why Mechanical Fasteners Slow You Down

Mechanical fastening methods — staples, rivets, nails, or even heavy-duty strapping — inherently require:

• Multiple manual steps: Positioning, fastening, checking alignment, and sometimes reworking misaligned closures.

• Special tools or equipment: Staple guns, nailers, or strapping machines that require maintenance and operator training.

• Additional safety precautions: To avoid injuries from sharp edges, recoil, or tool misuse.

These steps add up, often making mechanical fastening a multi-minute process per package, especially for complex crates, large furniture boxes, or protective assemblies.

2. How Industrial Tapes Streamline the Process

Modern industrial tapes are engineered for instant adhesion, replacing multiple fastening steps with a single, precise application. The benefits are immediate:

• One-Step Bonding: Peel, apply, and press — no extra tools, drilling, or fastening required.

• No Curing Time: Unlike some adhesives, tapes provide full bond strength instantly, allowing packages to move down the line without delay.

• Reduced Skill Requirement: Operators can be trained to use tapes effectively in minutes, minimizing onboarding time.

• Cleaner Work Environment: No debris from staples, no dust from drilling, no sharp waste to dispose of.

Example: Switching from stapling to high-tack carton sealing tape can cut closure time from 15–20 seconds to 5–7 seconds per package — a 65% improvement in speed. In large-scale operations, this translates to thousands of labor hours saved annually.

3. Tapes Designed for High-Speed Packaging Lines

Not all tapes are created equal. High-volume packaging requires tapes that combine adhesion strength, tear resistance, and dispenser compatibility. Examples include:

Tape Type	Key Feature	Best Application
BOPP Carton Sealing Tape	Fast unwinding, high tack, low noise	Standard corrugated boxes
Water-Activated Reinforced Tape	Tamper-evident, eco-friendly, high bond	Heavy goods, export packaging
Double-Sided Acrylic Foam Tape	Gap filling, vibration damping	Attaching foam inserts or panels
Filament-Reinforced Tape	Extreme tensile strength	Bundling heavy components

At New Edge, we provide both off-the-shelf and custom tape solutions — from pre-cut lengths for specific boxes to color-coded tapes that speed up product identification on the line.

Tape-based fastening systems can help manufacturers around the world save significant costs

4. Labor Cost Reduction Through Time Efficiency

In manufacturing economics, even small time savings per unit compound into significant cost advantages:

• Less Idle Time: Faster closures keep upstream and downstream processes moving smoothly.

• Reduced Workforce Needs: With higher output per worker, companies can maintain or even increase production with fewer staff.

• Minimized Overtime: Meeting daily targets without extended shifts reduces wage expenses and worker fatigue.

Illustration:If one operator processes 500 packages a day, switching to tape that saves 8 seconds per package frees up over 1 hour of labor per shift — per person. In a 20-operator facility, that’s over 500 labor hours saved per month.

5. Additional Operational Benefits Beyond Speed

• Consistency: Tapes deliver uniform sealing pressure and appearance, improving brand image.

• Safety: Lower risk of injuries from sharp fasteners or heavy tools.

• Versatility: Works on a variety of surfaces, shapes, and materials — from corrugated boards to foam panels.

• Branding Opportunities: Printed tapes can add instructions, logos, or handling icons directly on the package.

6. Case Example: New Edge OEM Packaging Optimization

A New Edge client in the export furniture industry used metal strapping and staples to secure large, flat-pack products. The process required three operators per line and an average of 2.5 minutes per package.

By switching to reinforced water-activated tape combined with foam edge protectors, we reduced closure time to 45 seconds, allowing the client to:

• Cut one operator per line without reducing throughput.

• Improve safety and ergonomics for workers.

• Present a cleaner, more professional final package for international buyers.

At New Edge, we offer a wide range of custom tapes for the packaging industry, serving both domestic and international markets

7. Conclusion: Tapes as a Competitive Advantage

In competitive manufacturing sectors, speed and efficiency are just as important as material quality. By replacing slow, labor-intensive fastening methods with industrial tapes, packaging operations can achieve:

• Higher throughput

• Lower labor costs

• Improved safety and appearance

At New Edge, we don’t just sell tape — we design complete tape-based fastening systems tailored to your product, packaging line, and performance requirements. The result: a faster, cleaner, more cost-effective packaging process that strengthens your bottom line.