Automated case sealing is an important part of efficient packaging lines, especially in high-volume industries such as eCommerce and consumer packaged goods (CPG). By reducing manual labor and improving consistency, automation helps facilities keep pace with demand. But there are persistent challenges that can disrupt these efficiencies, one being underfilled boxes.
Cartons that aren’t packed to the top, or those made with lightweight, thin-walled corrugate, introduce a unique set of sealing problems. While they might seem like minor inconveniences, underfilled cartons can significantly impact packaging line efficiency if not addressed properly.
The Challenges of Underfilled Cartons
1. Carton Collapse and Jamming
When a box lacks internal support, it is more vulnerable to external pressure. Automated case sealers apply downward force to hold the carton steady while packaging tape is applied across the flaps. For a full carton, this force is balanced and effective. But with underfilled cartons or low-volume boxes, the walls can collapse under the weight, causing the box to jam in the machine. Even one jam can lead to downtime and rework.
2. Inconsistent Seals
To properly secure packaging, the tape’s adhesive needs firm, consistent contact with the carton’s surface. When an underfilled box flexes under pressure, this contact becomes uneven. The result? Lifted tape edges or tape that fails to stick entirely. Poor seals don’t just look unprofessional; they increase the risk of product damage, potential for pilferage or theft as well as an underwhelming customer experience.
3. Increased Product Damage
Pressure from case sealing equipment can also impact what’s inside the carton. Fragile or lightweight items packed in underfilled cases are more susceptible to damage if the carton collapses or shifts during sealing. For businesses already navigating the high costs of shipping and handling, added product damage creates unnecessary expense.
4. Reduced Line Efficiency
Every case jam, incorrectly sealed box and need for rework pulls resources away from where they’re needed most. Operators are forced to stop the line, clear out cartons and rerun them, lowering overall throughput. Over time, inefficiencies caused by underfilled cartons can negatively impact productivity and lead times, especially in facilities with short staffing or high volumes.
A Smarter Way to Handle Underfilled Boxes & Case Sealing
Traditional case sealing equipment is engineered for uniform, full cartons. The machines assume that every box entering the system can withstand the pressure applied to achieve a strong tape bond.
However, in certain sectors, boxes vary widely in size, strength, and fill levels. Shipping small or irregularly packed products often results in underfilled boxes, and thinner corrugate is frequently used to reduce costs and material usage. This means that case sealing solutions designed for one type of carton are no longer sufficient for every application. That’s where ShurSEAL Underfilled Assist (UA) comes in.
Underfilled Assist is a packaging line enhancement feature designed specifically for sealing high-void fill, thin-walled and lightweight cartons without compromising speed or seal integrity. Integrated directly into ShurSEAL automated tape applicators, UA uses pneumatic precision to automatically adjust pressure when an underfilled carton is sensed.
For facilities navigating the growing number of underfilled cartons in their packaging mix, UA offers a low-impact, modular solution that integrates seamlessly into existing systems. The result is a smoother, more reliable packaging line that doesn’t get derailed by cartons that aren’t packed to the brim.
Keep Your Line Running Smoothly
Underfilled boxes may seem like a small detail, but their impact on case sealing can’t be ignored. From collapsed cartons to weak seals and wasted labor, the costs quickly add up.
ShurSEAL Underfilled Assist provides a practical way forward. It’s adaptable, keeps lines running smoothly, protects products, and ensures every tape seal is strong regardless of how full the carton is.
Packaging automation for underfilled boxes is a great first step to optimizing your line. Learn more about ShurSEAL Underfilled Assist.
