Why Carton Sealing Tape Fails in Cold Storage

When a taped carton opens in a coolroom or freezer, the immediate conclusion is often that the tape was not strong enough.

In practice, the problem may have started well before the carton entered cold storage.

The temperature at which tape is applied, the condition of the carton surface, how the tape was stored and the amount of application pressure can all affect the finished seal. A product described as freezer grade still needs to be used under suitable application conditions.

Freezer performance and application temperature are different

A tape may be designed to remain effective at low temperatures once it has bonded to the carton. That does not necessarily mean it should be applied to an icy or extremely cold surface.

Cyklop’s CT101 premium acrylic tape, for example, is described as freezer grade with good temperature resistance. Its technical information recommends applying the tape between 15°C and 25°C in a dry environment. It also states that the application surface should be dry and free from dust and particles.

This distinction is important for food producers, refrigerated warehouses and other businesses packing temperature-sensitive products.

Applying suitable tape to a clean carton before it enters the cold area may produce a very different result from taping the same carton after its surface has become cold or damp.

Condensation can interfere with the seal

Moisture between the adhesive and carton limits direct contact.

Condensation may form when cartons move between areas with different temperatures and humidity levels. A surface can appear clean while still carrying enough moisture to affect adhesion.

Wiping a visibly wet carton may not address the underlying process. The better question is whether the packing sequence can be arranged so that cartons are sealed while their surfaces remain clean, dry and within the tape’s recommended application range.

Cartons stored directly against coolroom walls, near doorways or beneath refrigeration equipment may also experience different surface conditions from those in the main packing area.

Cold tape may need time to recondition

Tape storage is another part of the process.

The CT101 technical sheet recommends storing tape between 15°C and 25°C, away from heat and light, with a maximum relative humidity of 65%. Where tape has been stored below 15°C, Cyklop recommends reconditioning it to the average application range before use.

Bringing a cold roll into a warmer packing area and using it immediately may not give it enough time to reach a suitable condition.

Businesses should also rotate stock and retain rolls in their original packaging where practical. Adhesive performance is not permanent. Cyklop’s technical information indicates that self-adhesive tape generally remains at its best for approximately 12 months when stored under the suggested conditions and protected from environmental extremes.

The carton matters too

Cold-storage tape should be tested on the actual cartons used by the business.

Two boxes that appear similar may have different surface coatings, fibre content or levels of dust. Recycled cardboard can also present a more variable surface than smoother board.

Cyklop offers acrylic and rubber adhesive tapes intended for applications including cold-temperature food packaging, recycled cardboard and general carton sealing. The appropriate choice depends on the carton and process rather than the temperature description alone.

The weight and contents of the carton matter as well. Internal pressure from an overfilled box, poorly folded flaps or products pressing against the top can place ongoing stress on the tape.

A stronger adhesive will not correct a carton that cannot close properly.

Application pressure should be consistent

Pressure helps the adhesive contact the carton surface. If workers lightly place the tape over the flaps without firmly applying it, the result may be inconsistent.

Hand sealing can work well at lower volumes, but outcomes may vary between operators and shifts. One person may apply a longer strip and press it down firmly, while another may stretch the tape or leave edges insufficiently bonded.

Where carton volumes justify it, a case sealer or tape machine may improve consistency. However, the machine still needs the correct tape, suitable tension settings and cartons that enter the process in an acceptable condition.

Test the complete cold-chain process

A tape trial should reproduce actual operating conditions rather than stopping once a carton has been sealed at room temperature.

A useful test may include:

1. Seal the actual production carton using the proposed tape.
2. Record the tape batch, carton type and application temperature.
3. Check that the surface is clean and dry.
4. Apply the tape using the normal hand or machine process.
5. Place the carton into its normal chilled or frozen environment.
6. Inspect it after realistic storage and handling periods.
7. Look for lifted edges, split tape, carton delamination or adhesive transfer.
8. Repeat the test across several cartons rather than relying on one result.

Where cartons move through several temperature zones, include those transitions in the trial.

Review the process before blaming the roll

Reliable cold-storage sealing comes from the combination of an appropriate tape, suitable storage, a clean application surface and a repeatable packing process.

Cyklop Australia’s packaging tape range includes products for general carton sealing, recycled cardboard, cold-temperature food packaging and high-volume machine applications. Testing the tape against the real carton and operating conditions is the most dependable way to determine suitability.