Packing Tape 101: Choosing Tape & Sealing Boxes
4 min read
What 'mil' means
Tape thickness is measured in mils (thousandths of an inch). Thicker tape is stronger and handles heavier boxes, but it costs more — match the tape to the load.
- 1.6–1.8 mil: Light parcels under about 30 lbs and general use.
- 2.0–2.5 mil: Standard shipping boxes and everyday e-commerce orders.
- 3.0 mil and up: Heavy boxes, double-wall cartons, and long-distance freight.
Acrylic vs. hot-melt adhesive
Both are clear and strong, with different strengths. Acrylic adhesive holds up across a wide temperature range and resists yellowing, making it great for long storage or hot/cold warehouses. Hot-melt has a stronger initial grab and works well for fast, high-volume sealing at room temperature.
Width and dispensers
Two-inch tape is the standard width for sealing most boxes. A tape gun (dispenser) lets you apply and cut tape one-handed, which is far faster and cleaner than tearing strips for any real volume.
Seal boxes with the H-tape method
The strongest seal covers all three seams. Run a strip down the center seam where the flaps meet, then run a strip across each end edge so the flaps can't pull apart — forming an 'H'. Do this on the bottom before you pack and on the top after. Make sure the box is clean and dry so the tape adheres.
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Frequently asked questions
How many strips of tape should I use on a box?+
Use the H-tape method: one strip down the center seam plus one across each end edge, on both the top and bottom of the box. Add more for heavy contents.
Why won't my packing tape stick?+
Tape struggles to bond to dusty, greasy, cold, or damp surfaces and to recycled boxes with a lot of fiber dust. Wipe the box clean, work at room temperature, and press the tape down firmly.
What's the difference between acrylic and hot-melt tape?+
Acrylic stays clear and sticks across a wide temperature range, ideal for storage. Hot-melt grabs faster and seals strongly at room temperature, ideal for high-volume packing.