Sustainable Packaging Part 1: Polybags with Recycled Content

tensionapdev on September 18, 2024

Tension’s polybags with recycled content offer a sustainable packaging solution that combines product protection, custom branding, and eco-friendly compliance, helping businesses meet evolving environmental regulations while reducing their impact.

Sustainable packaging is no longer just a trend—it’s becoming law across the U.S. States like Maine, Oregon, New Jersey, Minnesota, Washington, California, and Colorado have enacted Extended Producer Responsibility (EPR) laws, pushing businesses to adopt sustainable practices. More states are considering similar measures, and packaging is at the forefront of this shift. 

Your shipping packages play a critical role in not only delivering products safely but also maintaining your brand’s promise. Now, with sustainability taking center stage, these packages must also comply with environmental regulations. That’s where we come in. Tension’s polybags made with recycled content offer a sustainable packaging solution that aligns with your environmental goals. 

What is a Polybag Made with Recycled Content? 

At Tension, we offer L-LDPE polyethylene films containing post-consumer recycled (PCR) and post-industrial content (PIC). These polybags are a win-win for both product protection and environmental responsibility, offering up to 80% PCR content or more depending on testing. This percentage is a powerful marketing tool for brands committed to sustainability. Pair it with our fitPACK500TM system to create right-sized packaging that further reduces environmental impact through the use of less packaging material, which offers benefits throughout the supply chain. Stay tuned for Part 2 of this post to learn more about the sustainability-related benefits of fitPACK500.

Key Benefits of Polybags with Recycled Content: 

  • Custom Branding: Make a statement with logos and sustainability messages directly on the packaging. Highlight your eco-conscious efforts for customers who care. 
  • Recyclability: These polybags are recyclable at #4 plastic recycling locations, such as retail and grocery stores. 
  • Durability: Made with strong polyethylene materials, these polybags withstand the rigors of shipping, keeping products safe. 
  • Tested for Your System: Our packaging is rigorously tested to ensure compatibility with your machinery, minimizing wear and tear. 

Who Needs Polybags Made with Recycled Content? 

These polybags are ideal for businesses across a variety of industries, from fashion apparel, toys, sporting goods, jewelry, health and beauty items, home improvement, computer accessories, small electronics, home furnishings and more. For businesses looking to balance product protection with sustainability, Tension’s packaging solutions are the answer. 

Ready to Make the Switch? 

If you’re aiming to meet both branding and sustainability goals, our experts are ready to help. Contact Tension today to discuss the best polybag solutions for your unique needs. 

Three Ways to Incorporate Sustainability into Packaging Operations

tensionapdev on August 19, 2024

Incorporating sustainability into packaging operations can be achieved through the “Reduce, Reuse, Recycle” approach: reduce waste with right-sized packaging, design reusable packaging for returns, and prioritize recyclable materials—all contributing to a greener, more efficient supply chain and meeting growing demands for eco-friendly business practices.

Environmental concerns are at the forefront of consumer and corporate priorities. This is especially true in packaging and related industries: Businesses are increasingly looking for ways to make their operations more sustainable. Packaging, a critical component of product delivery, often contributes significantly to waste and environmental impact and companies are seeking to transform their operations to be more eco-friendly. 

Let’s explore three effective strategies for sustainable packaging with the help from a common slogan: Reduce, Reuse, Recycle. Reducing packaging through right-sized designs, reusing packaging for product returns, and recycling materials like paper and plastic. These steps not only benefit the environment but also enhance operational efficiency and meet the growing demand for sustainable business practices. 

Reduce: Create Right-Sized Packaging Tailored to the Product 

One of the most effective ways to incorporate sustainability into packaging operations is by reducing the amount of packaging used. This can be achieved by creating right-sized packaging tailored to the specific dimensions and protection needs of the product through solutions such as the fitPACK500TM. Right-sized packaging not only minimizes material use but also reduces the overall volume and weight, leading to lower transportation emissions and costs. This is especially relevant for packaging supplies for clothing, as consumers often order multiple sizes of a garment in pursuit of the best fit. By optimizing the size and materials of the packaging, businesses can significantly cut down on waste and contribute to a more sustainable supply chain. 

Reuse: Design Automated Packaging Equipment for Return Packaging 

Reusing packaging is another crucial aspect of sustainable packaging operations. One practical approach is to design automated packaging equipment for product returns. By including a mechanism to create a return strip on the package, it enables the package to function as a two-way for product returns if needed. This not only extends the life cycle of the packaging but also provides customers with a convenient and eco-friendly way to return items. For instance, durable packaging materials and easy-to-reseal designs can encourage customers to reuse packaging rather than discarding it after a single use. Implementing a returnable packaging system can significantly reduce waste and promote a circular economy. 

Recycle: How to Recycle Paper and Plastic Packaging

Recycling is an essential component of sustainable packaging operations. Businesses can prioritize the use of recyclable materials such as paper and plastic in their packaging designs. Encouraging customers to recycle packaging by providing clear instructions and information about recycling facilities can further enhance the effectiveness of this approach. Additionally, using recycled content in new packaging can help close the loop, reducing the demand for virgin materials and decreasing the overall environmental footprint. By integrating recycling practices into packaging operations, companies can contribute to reducing waste and conserving natural resources. 

Contact Tension Packaging & Automation 

Incorporating the reduce, reuse, and recycle concept into packaging operations can significantly enhance sustainability efforts for your company. By optimizing packaging design, encouraging reuse, and prioritizing recyclable materials, businesses can play a crucial role in promoting environmental responsibility and achieving long-term sustainability goals. Contact the experts at Tension to explore our sustainable packaging options today. 

Product Spotlight: fitPACK500™ Right-Sized Packaging System

tensionapdev on March 7, 2024

With its variable length, width and height capabilities, the fitPACK500TM is a right-sized packaging system that creates packages based on product dimensions, yielding shipping cost savings without compromising throughput.​

Growth in direct-to-consumer (DTC) business and labor shortages have led to increased investments in warehouse and packaging automation. Distribution operations are faced with needs for more throughput, cost performance in automated packaging equipment and sustainable solutions – all demands in addition to a changing warehouse model from eCommerce to a hybrid of eCommerce and retail fulfillment where split-case fulfillment and smaller pack sizes are needed to satisfy the new business model for warehouses. 

Our product innovation team is equally aware of the growth and changing needs in order fulfillment and have come up with the perfect solution in our new, innovative fitPACK500TM Right-sized packaging system. 

What is the fitPACK500 Right-sized Packaging System?

Designed by Tension Packaging & Automation, the fitPACK500 is a “right-sized” order fulfillment packaging system. It is designed for efficiency, reduces waste and creates cost savings. Tailored for variable sized items with capabilities to adjust package length, width and height for each product, it packages without compromising speed. Because the fitPACK500 can create a package according to size, it yields smaller, tighter, right-sized packages that lead to lower shipping costs.   

fitPACK500 Right-sized Packaging System Benefits

Through its innovative design, fitPACK500 offers warehouse distribution operations the ability to create packages according to the product size. This allows distribution centers to process orders with multiple products in varying sizes with right-sized packages, yielding reduced shipping costs and without compromising throughput. 

  • Productivity – fitPACK500 is custom-designed to create a right-sized package without compromising throughput.
  • Reduced Package Waste – Because fitPACK500 creates each package according to product size, package recipients receive packages with reduced package waste. A waste collection bin collects any excess width trim material.
  • Lower Shipping Costs – Because many carriers assign shipping costs according to package size, having the right package size helps get the correct shipping rate and can lead to significant savings on shipping costs over time.
  • Product Protection – Packages are custom-made to fit each product or grouping, creating secure, tight packages to protect the contents better.
  • Intuitive HMI – fitPACK500 is powered by Tension’s proprietary TensionCONNECTTM software that integrates any 3rd party systems. Its smart features include an intuitive user interface that reduces operator training time.
  • High Versatility – fitPACK500 can run different product sizes that call for different film widths through an intelligent 3D scanner. Its unique design allows operators to feed products without batching products or performing manual film changeovers.
  • Modern Modularity – fitPACK500 has enhanced options for further improving productivity. Available upgrades include complete packaging tracking capabilities and an option for “two-way” packaging with a perforation and adhesive strip for package returns.

Who Needs fitPACK500 Right-sized Packaging System?

Tension’s fitPACK500 Right-sized Packaging System is ideal for direct-to-consumer (DTC), business-to-business (B2B) or third-party logistics (3PL) order fulfillment operations who need automated packaging solutions. 

And as a full solutions provider, we offer integration solutions for any existing hardware or software solution in your facility. We also offer comprehensive service and support plans to lend our partners peace of mind in their dynamic and sometimes demanding warehouse environments.

Take a Tour of the Interactive fitPACK500 Product Video

With capabilities to adjust package length, width, and height, the fitPACK500 can create a package according to product dimensions, yielding smaller, right-sized packages that lead to lower shipping costs. Please tour fitPACK500 through our interactive video experience and learn why fitPACK500 is the perfect fit for your order fulfillment. Request your demo of this revolutionary right-sized packaging system here.

Contact Us

Give your order fulfillments operations the perfect fit for growth with Tension’s new, innovative fitPACK500 Right-sized Packaging System. Contact us to get started today or check our product page for more details. 

Getting Started with Automation: A Guide for Your Warehouse Management Solutions | Part 1, Business Assessment of Current Operation

tensionapdev on February 8, 2024

Assessing your current warehouse operations is the first step toward effective automation; by understanding demand, capacity, and growth goals, businesses can identify where automation solutions, like those offered by Tension Packaging & Automation, can alleviate bottlenecks, reduce overtime costs, and position fulfillment processes for scalable growth.

 

For all the buzz around automation in fulfillment and distribution operations, the casual observer who hasn’t automated their warehouse yet could be forgiven for thinking they’re the last ones to take the plunge. In reality, as recently as 2021 more than 80 percent of warehouses had no automation whatsoever. In some cases, that may be because those businesses took a close look at what they required to meet demand and concluded that they didn’t need automation. But it’s far more likely that they are part of the much larger group that isn’t sure what automation can achieve for them and, more importantly, isn’t sure how to get started implementing a warehouse management solution that would be right for them.

Growth is often the catalyst that pushes a business to move from curiosity regarding automation to an urgent need to do something to alleviate bottlenecks in their fulfillment processes. However, the wrong solution could potentially cost your business money without producing any significant benefit in accurate throughput. In this series, we’ll go through the steps to getting started on your automation journey to help ensure that your chosen solution meets your needs today and into the future. It begins with understanding what’s happening in your business now.

Taking a General Overview

Before you even begin looking at possible equipment and software, the first question is: How is your operation running today? Do you have enough people to keep things moving? Are you getting your orders out on time consistently? And if the answer to that last question is yes, are you using overtime to do so?

If you’re finding your existing workforce can’t keep up with demand on a regular basis, that’s an obvious problem that flags the need to consider automation. However, if you’re relying on overtime regularly to keep up, or surges in order volume routinely overwhelm your company’s ability to maintain timely shipments, these are also signs that your capacity is stretched to a point that limits your potential for growth. Leaning too hard on overtime also erodes your bottom line and runs the risk of burning out your workforce. In these cases, by expanding your capacity, automation helps to keep overtime expenses down and to reduce turnover.

Drilling Down on Specifics

Automation is a general term for different types of equipment, plus warehouse management software, that increase the volume of packages a fulfillment operation can process while optimizing accuracy. What configuration of packaging equipment, conveyor systems, and sortation systems will produce the greatest benefit for a company, however, depends on the specifics of how much and what they are shipping.

Volume is the first consideration. How many orders do you have going out per day? In our experience, around 500 to 1,000 orders a day is a point at which a warehouse should really be looking at options for integrating automation—but that’s a minimum, not a maximum. For a SLAM (Scan-Label-Apply-Manifest) system, it depends on the operation, but 500 orders per day is a general minimum where it starts to make sense.

Beyond that, it also matters what you are shipping and how. Are your products going out in boxes? Bags? What is the average mix per day? For example, if you’re shipping 500 packages per day, is it 200 boxes and 300 bags? This will help determine what type of conveyor and sortation systems would be best, as well as what type of automated packaging equipment might benefit your operation.

How Fast Do You Want to Grow?

The final factor you should be considering at this stage are the growth goals you have for your business in the near future. What are your growth plans in the next two to five years? What percentage of growth are you anticipating or aiming for per year? Twenty percent? Thirty percent?

You don’t have to invest in equipment that can instantly handle the volume your loftiest goals would demand, but you need to be sure your initial configuration is set up to give your operation room for immediate growth targets. You also want to be sure that your system can be readily adapted and augmented to keep pace with increased shipping volume and changing needs. The right solutions will make it easier to expand with a minimum of growing pains.

Your Automation Partner

If it’s time (or past time) for your warehouse to take a serious look at automation, Tension Packaging & Automation is your ideal partner. Our experience in taking eCommerce and pharmacy operations from little to no automation to customized systems that optimize productivity allows us to guide those just starting their automation journey. We’ll assess your needs, make recommendations that support your business goals, integrate your chosen solutions into your existing processes, and provide the training and support essential to ensure you get the most out of your automation investment.

Ready to get started? Contact Tension Packaging & Automation today to discuss your distribution needs.

Top 4 Benefits of Tension’s PharmaPATH™ Back-End Pharmacy Workflow Software

tensionapdev on September 28, 2023

In pharmacy operations, there’s no room for error or delays—patients depend on receiving the right medications quickly and accurately. Tension Automation’s PharmaPATH™ workflow software streamlines order fulfillment with features like dedicated task workstations, barcode verification for accuracy, and an intuitive touchscreen interface. Designed for adaptability, PharmaPATH ensures your pharmacy operates at peak efficiency while staying customizable to grow with your business.

Whether you’re running a mail order, central fill, specialty, or hospital outpatient pharmacy, there’s no room for error in filling prescription and nonprescription orders. It’s also not acceptable to sacrifice speed for accuracy—when patients are waiting on their medications, they rely on their pharmacy to supply exactly what they need when they need it.

Unfortunately, the process of taking fully confirmed order requests and turning them into prescriptions that have been accurately and quickly dispensed, verified, packaged, and manifested is full of opportunities for mistakes and inefficiencies to creep in, especially when a growing volume of orders threatens to overwhelm your current capacity. Whether you’ve automated dispensing, fulfill orders manually, or have a hybrid setup, Tension Automation’s PharmaPATH back-end pharmacy workflow software is an easy-to-use solution that optimizes efficiency and increases productivity from start to finish.

How does PharmaPATH make your job easier while giving you the peace of mind of knowing that every order is going out accurately filled? Here are the top four benefits of our software:

  1. Dedicated Task Workstations – Everybody knows that systems that require multiple tasks and processes per screen inevitably slow things down, forcing users to continually shift gears as they complete steps. Worse, attempting to speed up such layered tasks to keep up with demand can cause mistakes. Our dedicated workstations allow your pharmacy technician or pharmacist to focus on one thing at a time, resulting in reduced processing time overall. The operator is able to excel at a single task rather than juggling many.
  2. Accuracy Scans – Barcode scan verification means that accuracy is literally built into every step of the process. Reduce time lost to correcting errors.
  3. Rapid Processing Time – Scans don’t just enhance accuracy; they also only take seconds to process. (Compare that to the time it would take an operator to read and verify a label, feeling confident they’d gotten it right.) In addition, WFS is programmed for intelligent order monitoring, determining the fastest processing method for each item dispensed. In combination, these allow for higher throughput.
  4. Touchscreen-Based User Interface – Our UI is simple, intuitive, and designed to reduce training efforts, increase throughput, and eliminate mistakes. Color-coded direction buttons on the human-machine interface (HMI) direct users to the next step in the process, telling them exactly what to do. Our software eliminates the need to use a cumbersome keyboard AND mouse alongside a touchscreen.

Made for You: Adaptable and Customizable

The beauty of our back end pharmacy WorkFlow Software is not just that it speeds up accurate pharmacy order fulfillment, but that it is designed to be modified to fit your unique workflows, rather than trying to shoehorn your operations into a one-size-fits-all box. We also know that a successful operation is one that changes, so WFS can also be adapted to add additional processes as your company grows.

Tension’s PharmaPATH also includes a customizable dashboard that gives you at-a-glance visibility into your operations. Track your inventory, monitor which orders have been fulfilled, and stay on top of your output targets. This too can be customized as your business grows and evolves, depending on what data points you need to track.

Best of all, PharmaPATH is backed by Tension’s outstanding customer service. We’re here to ensure that your system is fully customized to the workflow of your pharmacy operations, to provide the necessary training to get your workforce up to speed, and to help you realize the full value of your investment. We’re also here to provide ongoing support and customization as needed so your system always keeps pace with the needs of your business.

Your Source for Pharmacy Solutions

As a leader in packaging equipment and automation systems specializing in pharmacy and eCommerce, Tension Packaging & Automation is dedicated to helping our customers optimize productivity with results-driven solutions. To find out more about how our back end pharmacy WorkFlow Software can improve the efficiency and profitability of your pharmacy operation, contact us here today.

eCommerce Automation: A Guide to Automating the Last 100 Feet, Part 2: SLAM Optimization

tensionapdev on September 21, 2023

Increased sales are great news for your eCommerce business—until your fulfillment operations struggle to keep up. A SLAM (Scan, Label, Apply, Manifest) line can streamline the shipping process, reducing errors and bottlenecks while increasing throughput. From automated labeling to precise sortation, Tension’s SLAM solutions ensure efficiency and accuracy, allowing your business to scale without sacrificing quality.

Increased sales can be a cause for elation in an eCommerce business, or they can be a rock smashing your fulfillment operations against the unrelenting hard place of insufficient labor to meet demand. In Part 1 of this series, we examined the role of right-sizing your packages in keeping shipping costs down and how automation can help you accurately calculate DIMs, efficiently shop for the best rates, and avoid costly adjustments and fees. Now we’ll take a look at the other features of a scanning, labeling, application, and manifesting (SLAM) line and how they work in concert to improve accuracy and throughput.

The Many Steps of Sending a Package Out the Door

Preparing a package to ship to a customer requires a sequence of steps that introduce many opportunities for bottlenecks or errors, especially if you’re relying on an overworked manual labor force. Once the products are packed into a carton or bag, that package must be weighed and measured (again, see Part 1 for the errors and problems that can arise here). Then it must be labeled for the correct recipient and shipping service, and routed to the right carrier to head out on its way.

It’s easy to see where mistakes can creep into repetitive tasks when workers are pressed for time trying to keep up with surges in demand. Wrong label on a package. Box deposited in the wrong bin for shipping. Worse, injuries can result from repetitive motion or from accidents when there’s a rush to get too much done. Automating this process not only drastically reduces these kinds of issues, but also frees up your employees for higher-skilled tasks. Here’s how.

Labeling and Sortation

A package’s SLAM line journey starts with packaging and dimension and weight capture. But that’s just the beginning of how automating the last 100 feet can optimize your fulfillment operations.

  • Print & Apply Labeling: This station assures that the right package is addressed to the right person per the label. It can label bags or cartons, assuring that the line stays moving even when dealing with a variety of package types and sizes. Custom labels are also available, so your packages can fit in seamlessly with your overall marketing strategy.
  • Sortation Scanner: At this station, the package is identified and diverted to the appropriate carrier and class of service with the assistance of our Tension Director software.
  • Z-Sorter for Shipping Sortation: Here packages are routed to the appropriate carrier, using our proprietary waterfall design that works with gravity to create a smooth sorting operation. The sorting machine is modular, so additional sortation units can be added or removed to meet your operation’s needs, depending on volume, carrier selection, shipping regions, and more.

The result from start to finish is an increase in efficiency that allows you to process hundreds of orders per hour, with an improvement in accuracy that reduces costs as packages flow through the system. Best of all, Tension Automation’s SLAM lines are fully customizable, allowing you to adopt a solution that is configured exactly to the unique requirements of your distribution center.

Your Expert eCommerce Automation Resource

If you’re ready to talk about how automation could help your business but have been paralyzed because you don’t know where to start or what improvements will have the greatest impact, Tension Packaging & Automation can help. We can assist in examining your current processes and capabilities, determining your goals for automation, and figuring out the right equipment to implement an effective strategy.

In addition to designing, building, and installing warehouse automation solutions for eCommerce fulfillment, Tension is also your partner in training, service, and ongoing support. As your needs change, we’re here to ensure that your packaging equipment and automation solutions are optimized to grow with your business and that your investment pays off for years to come. To learn more about the benefits of a SLAM line in your business, contact us today.

#likeaboss: Top Three Ways to Handle Labor Shortages During Your Peak Season

tensionapdev on August 29, 2023

The holiday season is fast approaching, and with it comes a surge in eCommerce orders and inevitable returns. For retailers facing labor shortages, automation offers a lifeline to keep fulfillment operations running smoothly. From full automation to hybrid solutions, Tension Automation provides scalable options to optimize efficiency, meet peak-season demand, and deliver a strong ROI.

With the biggest shopping season of the year nearly upon us, eCommerce retailers bracing for a flood of holiday orders (and the returns that follow) may be facing a sobering realization: they don’t have the workers to get those orders shipped.

Economic news has been mixed over the last year, leading to early predictions that retail sales will only grow modestly from 2022 numbers. However, the recession many economists expected hasn’t materialized—despite rising interest rates, inflation has been declining, wages are going up, families are continuing to spend, and unemployment is low. How low? As of July 2023, it sat at 3.5%, according to the Bureau of Labor Statistics.

You know peak season is coming. Holiday purchases start in October, spiking on Black Friday and over the Thanksgiving weekend and staying strong through the holiday season. January is also a busy shipping month, with the inevitable returns that occur after all the presents have been unwrapped.

If your past solution has been to add staff to ensure orders are processed and on their way before holiday shipping deadlines with the major carriers, the numbers aren’t on your side. That’s no reason to panic, though. You can still stay on top of order fulfillment (like a boss) with automation solutions that let you make the most of the workforce you have.

Automation Solutions to Overcome Labor Shortages

Every eCommerce order fulfillment company is different, which is why Tension Automation offers a range of options to allow you to introduce automation to your system to enhance your efficiency and accuracy. What are the possibilities?

  • Solution #1 – Full Automation – Did you know that on average, implementing automated packaging equipment can yield 4x package throughput? A fully automated line with packaging equipment and a SLAM (Scan-Label-Apply-Manifest) line that automatically scans, weighs, and identifies package dimensions to handle the DIMs, labeling, and sortation part of your order fulfillment process can help minimize the challenges that come with labor shortages.
  • Solution #2 – Semi Automation – Manual packaging stations with a SLAM line; if, for example, your product doesn’t lend itself to automated packaging, you can still optimize the last 100 feet of your order fulfillment process, devoting your labor pool to getting packages ready while the DIMs, labeling, and sortation are automatically handled.
  • Solution #3 – Hybrid – Integrate an automated packaging system, conveyors, sortation, a DIM scale, a print and apply label system, or a combination of these elements to eliminate costly bottlenecks in your order fulfillment processes. Not sure what you need? Tension Automation is an industry expert at integration. We can consult on a new layout and seamlessly implement a customized solution with our integration software.

Measurable Savings with Automation

Automation is an investment in your business with measurable financial benefits that boost your bottom line. Consider these advantages:

  • Less Labor: Strategic automation increases order fulfillment without increased hiring, meaning your operations won’t be held back by a lack of personnel at critical times (or the training required to bring permanent or temporary workers up to speed). Keep your payroll lean and focus your staff’s valuable expertise on high-skilled tasks.
  • More Throughput: Consumer loyalty is fickle—one study reported that 69 percent of respondents were much less or less likely to shop with a retailer again if their delivery wasn’t made within two days of when they expected it. Automation helps you prevent order backlogs that can affect future sales.
  • Short ROI: In addition to improving overall fulfillment speed and cutting down on labor costs, automation can reduce errors and the amount you pay for shipping. Typical time to realize a full return on your investment is only 12 to 18 months.
  • Bonus Savings: A variable packaging system can accelerate your ROI by reducing your use of consumable shipping materials.

Staying Ahead During Peak Season

When increasing orders and limited staffing are on a collision course in your order fulfillment operation, automation can help keep you effortlessly ahead of the curve. Tension Automation has a variety of flexible, expandable, easily integrated solutions to make you the boss of peak season this year and every year. Contact us today to learn more about your options.

Heat Seal vs. Cold Seal Packaging: Which Option is Right for Your Packages?

tensionapdev on February 8, 2022

With global parcel volumes projected to double by 2025, selecting the right packaging equipment is crucial for handling increased demand. Heat seal packaging offers strong, weather-resistant seals ideal for clothing and soft goods, while cold seal packaging is perfect for dense items like books and electronics, offering cost and productivity benefits. Tension Packaging & Automation provides tailored solutions to optimize your operations and meet your growing needs.

According to a recent study, global parcel delivery volumes will increase by 100% by 2025. In addition to their annual peak season rushes, retailers and order fulfillment companies have a need to prepare for greater package volumes to come over the next few years.

When choosing equipment for your operations – and especially as you plan for growth – understanding the difference between heat seal and cold seal for packages can help guide your overall logistics strategy.

What is Heat Seal Packaging?

As the name implies, heat seal packaging uses heat to melt the sides of film packaging together to create a seal. In packaging applications, a heat seal can be used to both create a bag from two sheets of poly film and/or to secure the bag closed.

Heat Seal Benefits

  • Protective Material: This material provides a strong package that helps to protects contents from harsh weather conditions, such as rain or snow (and the lighter weight material can possibly reduce shipping costs).
  • No Adhesives Required: Because a heat seal uses heat to create the seal, there is no need for special pressure-sensitive adhesives.
  • Increased Productivity: Using one of Tension’s automated heat seal solutions, you can pack and prepare 8-16 packages for shipment per minute, on average, vs. 1.5 packages per minute using a hand packing method. Additionally, the variable length system helps create a right-sized package that could save you on shipping costs.

What is Cold Seal Packaging?

Cold seal packaging refers to water-based adhesives that are used to seal paper (e.g., kraft corrugate) and film packaging material. Cold seal is a self-sealing type of closure, only requiring pressure to create the seal on a package.

Cold Seal Benefits

  • Product Protection: Box-style packages* created from a cold seal eliminate the need for void fill, which creates increased protection for products inside.
  • Increased Productivity: Keep your machine running fast with easy-to-use features like batch processing or length adjustments for variable sized packages with capabilities of up to 8-16 packages for shipment per minute.
  • Cost Controller: Because cold seal packaging equipment requires no heating elements, it reduces costs related to electrical consumption.

Heat Seal vs. Cold Seal: Who Uses It?

A cold seal is ideal for companies packaging harder, dense products, such as books, CDs, DVDs or video games. Conversely, a heat seal is an ideal solution for companies packaging clothing, soft goods, shoes and other boxed items.

Contact Us

All packaging equipment is not created equal: Your products often dictate your seals and other packaging needs. Contact an expert at Tension to learn about solutions that can help optimize your productivity.