Picking the right automated case sealer can make a big difference in how smoothly your packaging line runs. Whether you're considering trusted brands like BestPack, 3M, IPG (Intertape Polymer Group), Eastey, or Wexxar Bel, the key is avoiding a few common mistakes that can cost you time, money, and a whole lot of frustration.
Case sealers are designed to save time and boost consistency by sealing boxes quickly and reliably. But if you choose the wrong one for your setup, it can create more work than it solves.
In this blog, we’ll go through the common mistakes businesses make when choosing a case sealer—and how to avoid them—so you can find the right fit for your operation and keep things running smoothly.
When choosing a case sealer, consider the sizes of the boxes you'll be sealing. If your business runs a mix of box sizes throughout the day, you’ll want to look at a random case sealer. These machines are versatile and automatically adjust to different box dimensions, saving time and keeping things moving smoothly.
But if you're mostly sealing the same size box or doing long runs of a single size, a uniform case sealer might be a
Now, here’s something else that’s just as important but often overlooked: box type. Whether you're using FOL (Full Overlap) boxes, RSC (Regular Slotted Cartons), or another box style, this can impact which sealer will work best. Some machines handle heavier or more complex box designs better than others, so it’s worth matching the sealer to the box style, not just the size.
Bottom line? Think about both the range of sizes and the types of boxes you’re sealing. It’ll help you choose a machine that fits your workflow and keeps your packaging line running efficiently.
Check out the case sealer options for your business here to find the right match for your box sizes and types.
Think about how fast you need the boxes sealed. Different operations have different speed requirements, and picking the right machine can make a big difference in your efficiency.
If your business processes a lot of packages every day (more than 100 boxes a day), you'll need an automatic case sealer. These machines are designed to keep up with fast production lines and can significantly increase throughput. Your packaging line will run smoothly and efficiently, helping you meet your daily targets without hiccups.
A semi-automatic box sealing machine might be more suitable if your operation is smaller or has lower volume requirements. These machines are more cost-effective and can still provide reliable sealing without needing high-speed capabilities. They are ideal for businesses that don't need to seal boxes rapidly but still want consistent results.
Chat with an Equipment Specialist here to find the right case sealer for your business and make sure you get the machine that matches your speed needs.
Another big decision when choosing a case sealer is figuring out how much automation you really need. This can make a huge difference in how efficient your packaging line runs—and how much you spend on labor.
A fully automatic machine might be the way to go if you're running a high-volume operation and need to move boxes fast. These sealers do it all—folding flaps, sealing top and bottom—without anyone needing to touch the box. They’re built for speed and consistency, which is perfect if you're sealing hundreds (or thousands) of boxes a day and want to keep labor costs down.
On the other hand, if your setup is a bit smaller or you’re just starting to automate, a semi-automatic machine could be a better fit. These still save a ton of time compared to sealing by hand, but they give you more control and flexibility. You’ll need someone to position the box and maybe fold a flap or two, but the machine takes care of the sealing. They’re also easier to adjust for different box sizes and types, which is great if your packaging needs change often.
So, whether you're scaling up or starting in automation, choosing the right level of automation can really streamline your workflow—and make your team’s job a whole lot easier. View new and used in-stock case sealer options here to see what options are available and ready to ship out to you right away!
Let’s be honest—maintenance isn’t the most exciting part of choosing a case sealer, but it’s one of the most important. Skipping over this can lead to unexpected downtime, costly repairs, and a lot of frustration down the line.
Some machines need more frequent maintenance than others. If a machine requires a lot of upkeep, it can lead to downtime if not managed properly. Look for machines that have low maintenance needs and are known for their reliable performance.
It's important to see how easy it is to get spare parts for your machine. If something breaks and you’re stuck waiting weeks for a replacement, that’s time (and money) lost. Go with a brand or supplier that keeps parts readily available.
Even the best machines can run into issues, so having access to solid technical support is a big deal. When something goes wrong, you want to know there’s someone you can call who’ll pick up the phone and help.
One of the best ways to stay ahead of all this? Working with a company that offers a preventive maintenance plan. It takes the guesswork out of keeping your equipment in top shape. Regular check-ups, scheduled service, and fewer surprises. It’s a simple way to keep your line running smoothly without the stress.
Want to take the hassle out of maintenance? Check out Rapid Packaging’s Preventive Maintenance Plan and see how it can keep your equipment running.
Tape might seem like a small detail, but it can make or break your sealing process—literally. Using the wrong tape (or using it the wrong way) can lead to weak seals, wasted materials, and unnecessary downtime. So, let’s talk tape.
Not all tapes are created equal. Some are built for strength, others for speed. Let's explore two options:
High-performance tape
Strong adhesion and durability
Built to handle tough conditions
Great for:
Heavy boxes
Rough handling
Demanding environments
Designed for speed and ease of use
High tack (sticks quickly and effectively)
Ideal for:
High-speed packaging lines
Operations focused on efficiency
Lighter or standard box loads
It’s tempting to tweak the tension on the tape head to “fix” a sealing issue, but that can actually cause more problems than it solves. Too tight, and the tape stretches and won’t stick properly. Too loose, and you get sloppy seals or tape jams. Tape is pressure-sensitive—it just needs the right amount of pressure on the box, not a stretch workout.
Getting the right tape—and using it correctly—keeps your seals strong, your machines running smoothly, and your packaging line efficient.
Want to make sure you're using the best tape for your setup? Learn more about tape options here and find the right one for your application.
Even the best case sealer won’t perform well if your team doesn’t know how to use it. Proper training is key to keeping things running safely and efficiently. What to keep in mind:
Look for machines with intuitive controls. A simple, easy-to-navigate interface helps your team get up to speed quickly, reduces errors, and keeps productivity high.
Good manuals, quick-start guides, how-to videos, and in-person training sessions can make a big difference. The more accessible the training, the more confident your team will be.
It's a good idea to have a few go-to people on your team who really know the equipment. They can help train others, troubleshoot issues, and keep things running smoothly.
Think about your future growth. It’s easy to focus on what you need right now, but as your business expands, you'll need a machine to meet increased production demands. The right case sealer should grow with your business.
Choose a machine that can handle more volume as your production ramps up. It’s often more cost-effective to invest in a scalable solution now than to replace it later.
Machines with flexible settings let you tweak speed, box size, and other features as your needs evolve. That kind of adaptability can save you time and money down the road.
Make sure your case sealer can integrate with other packaging equipment, such as conveyors, labelers, or automated systems. A well-connected line means smoother scaling when the time comes.
Thinking ahead now can save you a lot of hassle (and expense) later.
Avoiding these common mistakes can help you choose a case sealer that fits your business today—and tomorrow.
Here’s a quick recap of what to keep in mind:
✅ Box sizes and types
✅ Speed and automation levels
✅ Maintenance needs
✅ Tape compatibility
✅ User training
✅ Future scalability
Each of these plays a role in making sure your packaging process is efficient, reliable, and ready to grow with you.
Click here to chat with a Packaging Specialist to discuss your options and find the best fit for your packaging line