Customer Overview
A leading consumer goods manufacturer supplying retail‑ready packaging to major big box retailers sought improvements in case sealing performance, appearance, and
compliance to meet stringent retail and
automated warehouse standards.
The Challenge
Glue‑sealed cases were failing during transit and on retail shelves, creating pilferage risk, poor shelf appearance, and exposure to retailer fines from automated systems that detected improperly sealed boxes.
Proposed Solutions
IPG partnered directly with the manufacturer to convert top seals from glue to tape on key retail‑ready case formats. The implementation of IPG’s 7100 1.9 mil carton sealing tape in
combination with IPG’s ET Xtreme® tape heads ensured consistent, secure seals that met the retailers requirements.
Case designs were optimized, including
converting from a 1” gap to a 2.5” gap using 4” machine‑applied tape with an IPG tape head to reduce in-store pilferage issues. IPG also supported standardization of automatic case sealers built with ET Xtreme tape heads and provided quarterly preventive maintenance to ensure long‑term performance and reliability.
Results
The tape conversion eliminated top‑seal failures associated with glue, keeping cases securely sealed through distribution and on retail shelves. Improved appearance enhanced merchandising, while reliable sealing reduced pilferage and exposure to retailer fines.
Operational consistency improved through standardized equipment, reduced downtime, and proactive tape head maintenance. Following initial success, additional product lines progressed toward glue‑to‑tape conversion.
Results
This project demonstrated how IPG’s tape, equipment, and service capabilities can transform retail‑ready packaging performance for consumer goods manufacturers supplying big box stores. As a result of this success, IPG has received additional opportunities to evaluate similar glue‑to‑tape conversions across other product lines and facilities, expanding the impact well beyond the original implementation.