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Introduction
This article takes an in-depth look at Poly Bags.
You will learn about topics such as:
What is a poly bag?
How poly bags are made
Uses for poly bags
Types of poly bag materials
And much more …
Chapter 1: What is a Poly Bag?
A poly bag is a common shipping and packaging resource made of polymer material that is exceptionally durable, pliable, and customizable to fit any application. Made of polyethylene or polystyrene materials, poly bags are a precisely engineered and designed compact method for protecting and securing products, parts, and merchandise.
Though polyethylene was introduced during the first industrial revolution, it wasn‘t until the 1950s that it was turned into the poly bags we see today. The growing popularity of poly bags is due to the need for an inexpensive, sturdy, and useful method of transporting goods safely and securely.
Chapter 2: How Poly Bags are Made
The production of poly bags involves highly technical and scientifically engineered processes that are precisely planned to ensure high quality results. All forms of poly bags begin with high resin plastic pellets that produce the required type of film and gauge.
All poly producers rely on the heating and extruding of the resin pellets, which are made from ethylene or propylene that are extracted from natural gas. In ethylene and propylene are hydrocarbons that are used to make monomers from a cracking process. From the monomers comes the polymerization reaction to produce polymer resins for the manufacture of poly bags.
Resin or Plastic Pellets
The type of resin selected for the manufacture of a poly bag determines the durability, weight, and thickness of the bag. There are five types of resins used to produce plastic bags: high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), and polypropylene (PP). The characteristics and properties of these polymers are the major factors regarding a bag‘s strength and life expectancy.
The creation and manufacture of high quality poly bags begins with the selection of the correct bag materials.
Extrusion
Once the resin has been selected, it is loaded into the hopper of an extruder. The initial method for melting plastic pellets was to simply heat them in a vat or large barrel. The result was an uneven heating of the material with pellets closest to the heat source being hotter and more pliable.
This led to the development of the extruder, a screw mechanism that evenly heats the material at 350°F to 450°F such that all of the pellets are melted to the same temperature. An extruder is screw-like with a loading hopper at one end and a die at the other. The resin is fed into the hopper, which slowly drops the resin into the barrel of the extruder. As the screw turns, the pellets move along the length of the extruder, heated by heating units placed along the length of the barrel.
Inflation
The molten plastic resin exits the extruder die in the shape of a tube and is inflated and stretched to the needed size and shape of the poly bag. The tube is inflated using air, which creates the desired thickness of the plastic film. The rate at which the tube is inflated and the cooling process affect the thickness and properties of the polyethylene film.
Cooling Tower
Once the tube of plastic is fully extended, it remains in the tower until it cools. In the cooling tower, it has the appearance of a tall plastic vertical balloon. As it expands upward, it comes into contact with the walls of the tower and cools as it works its way up to the cutting rollers. Cooling is a critical step as it determines the final properties of the polyethylene film.
Nip Rollers
To make the plastic fabric, the tube passes through the collapsing frame before entering the nip rollers that flatten it into a lay flat form to be rolled into a large roll of plastic. Nip rollers provide high traction, isolate web tension zones, and improve winding onto a roller.
Nip rolling can be used to control the thickness of poly bags. By adjusting the gap between the rollers and the pressure applied, manufacturers can ensure consistent thickness throughout the bags.
Rolling Film
Once the inflated film is flattened and passes through the collapsing frame and nip rollers, it is rolled into a huge roll for processing. Roll winding machines carefully wind the plastic film onto cores or spindles. The size and length of these rolls can vary based on your needs and the capacity of your equipment. It is from these rolls that the poly bags will be printed, formed, cut to lengths, and sealed.
Flexographic Printing
Poly bags come in different sizes, thicknesses, colors, and forms. Bags that are produced for stores, shops, and retail outlets usually have print identifying the store with some of the printing offering additional information. Printing on poly bags is done by a process known as flexography, a roll feed web printing process used to print on film, foils, paper, cardboard, and other materials.
The image to be transferred is imprinted on a polymer plate using ultraviolet light. The image is engineered and designed on a computer using design software such as CAD. The negative of the image is placed on a light sensitive polymer plate. When it is exposed to ultraviolet light, the image hardens while the material around it turns to a gummy substance that is washed away.
The completed plate is wrapped around a cylinder. As the poly material passes between two cylinders, one with the plate on it, the plate is wetted with ink and prints the image on the bags. For single color printing, one plate and set of cylinders are used. When multiple colors are necessary, the poly bags will pass through a series of cylinders, each having a different portion of the image.
Cutting
During the printing process, the roll of film from the extruding and blowing process is unrolled as it passes through the flexographic printer. After the poly bags are printed, they are re-rolled in preparation for the cutting process.
Every manufacturer has their unique process for cutting poly bags, which includes the sealing of the bag. Handles may be cut and shaped in addition to cutting the bag to length.
Additionally, the cutting process has to allow for gussets that may have been added during the cooling of the plastic tube after extrusion.
Poly Bag Production
Though numbers vary, poly bag producers can process as many as 70,000 bags an hour, depending on the size, type of polymer, and length of the bag. Larger and longer bags are produced at 2,000 bags per hour.
Hourly production of poly bags is dependent on the size of the bag and the thickness of the polymer, which is significantly altered by thicker, longer, heavier bags.
Poly Bag Thicknesses
The ply of a poly bag refers to its strength, durability, and ability to protect materials. The strength of a poly bag is dependent on its thickness, which is determined by its mil score, an industry measurement for poly bag thickness or gauge with one mil equal to 0.001 of an inch. The majority of poly bags are 6 mil or less with the average thickness being 2 mil.
Poly bags are manufactured to 10% of their minimal thickness, which means that a 2 mil poly bag will be 1.8 mil or 0.0018 inch thick. When a customer orders a poly bag, they need to specify whether the bag will have minimal thickness or full gauge thickness.
Common Mil Type Thicknesses and Their Use
Thickness in Mils
Thickness in Inches
Uses
<1
0.0005-0.00075
Meant for short-term use requiring little protection, such as produce bags or dry-cleaning bags.
1-2 3
0.001-0.002 0.003
Moderate protection for storing, shipping, or displaying items like food, clothing, or retail products.
4 5 6
0.004 0.005 0.006
Heavy-duty protection heavy or products. Can also be tear and scratch-resistant for added durability. Ideal for storing bulk items like screws or parts or large industrial uses such as pallet covers.
There are three factors to consider when choosing the correct poly bag mil to fit a product.
Product Weight and Size
Level of Required Protection
Necessary Durability and Shelf Life
Leading Manufacturers and Suppliers
Chapter 3: Uses for Poly Bags
The many options and designs for plastic bags has made them an essential part of society. Poly bags have become so common that they are taken for granted as a means for packaging, shipping, and handling a wide array of products. Though poly bags have a very basic function as a tool for transporting goods, their use has expanded far beyond their original purpose.
When poly bags were first introduced as a way to package a customer‘s purchases, they were clear or plain white. Once it was obvious that poly bags would be common, marketers saw an opportunity to expand the use of the bags as a means for making a company‘s or product‘s logo visible, which led to the printing of information on the sides of the bags.
Pallet Bags
Pallet poly bags help to keep materials on a pallet and protect them from the elements. They are ideal for shipping purposes for equipment, machinery, products, and inventory supplies. A major feature of pallet bags is their ability to expand to snuggly fit any type of pallet load.
Pallet poly bags can also be designed with security features or tamper-evident seals to protect the contents from unauthorized access or tampering during transit.
Food Bags
Poly food bags have been on the market for many years as a means of protecting the quality and cleanliness of food. The various types of poly food bags keep moisture, air, and atmospheric contaminants away from displayed food products. The many designs include those that can be vacuum sealed such that air is removed from the interior of the bag, enhancing its protective qualities.
In order for a poly bag to be classified as a food service or storage bag, it is required to meet the standards established by the Food and Drug Administration (FDA) as well as those of the United States Department of Agriculture (USDA). Poly bags that have met the requirements have indications stamped on the bag.
Box Liners
Box liners are designed to keep products and supplies clean, safe, and protected. They serve the same purpose as pallet bags by providing durable protection when materials and items are in storage. High density polyethylene liners have excellent strength and durability and are available in several sizes to fit any box.
Poly box liners act as a moisture barrier, preventing moisture from entering the box and potentially damaging the contents. This is particularly useful for products that are sensitive to humidity or water, such as electronics or food items.
Trash Bags
Poly trash bags have become a more common household item, available in sizes to fit any type of trash can, from large bags for yard waste to small bags for office trash cans. Many waste management companies require their customers to put their non-recyclable trash in heavy duty trash bags. Possible trash bags selections include those that have odor suppressors, draw strings of varying types, and handles. The various innovative designs have greatly enhanced the trash collection industry.
They are available in different colors, which can help users segregate and identify different types of waste or simply choose a color that matches their preferences. Poly trash bags are designed to be strong and puncture-resistant, making them suitable for holding a variety of waste materials, including sharp or heavy objects. The various innovative designs have greatly enhanced the trash collection industry.
Poly Anti-Static Bags
Poly anti-static bags minimize static electricity and protect against damage from electrostatic discharge (ESD). They are designed for the storage and packaging of electronic components that may be damaged by environmental ESDs. Manufacturers offer various forms of poly anti-static bags, which are air tight for water protection and contain fire retardant material.
Many poly anti-static bags are transparent or translucent, allowing for easy identification of the contents without opening the bag. This feature is useful in environments where components need to be visually inspected or inventoried.
Poly anti-static bags are commonly used in the electronics industry, including manufacturing, assembly, shipping, and storage of sensitive electronic components and devices. They are also used in other industries where ESD protection is essential, such as aerospace and medical device manufacturing.
Mailer Bags
Mailer or shipping bags are used for shipping products and avoiding the weight of boxes. There are several varieties of mailer bags, including those with a zip closure, pressure closure, and peel and seal. The seal on mailer bags protects shipped products from environmental contaminants and the weather. Some companies use mailer bags as a way to display their logo and offer brand visibility.
Mailer bags are typically more cost-effective than traditional cardboard boxes, both in terms of the packaging material itself and the shipping costs. They can be customized with branding, logos, and designs, making them a popular choice for businesses looking to create a professional and branded shipping experience.
Zipper Bags
Zipper bags are one of the most used bags on the market due to their toughness and durability. They are available in a wide range of sizes for simple shelf storage or freezer storage. Zipper bags keep food fresh and organized, extending the shelf life of perishables and preventing freezer burn. They're a go-to for meal preppers, neatly storing portions of soups, sauces, and snacks. They ensure leak-free and convenient packing of toiletries for traveling, reducing the hassle of spills in luggage. For students and professionals, zipper bags are essential for organizing stationery, documents, and gadgets. They are also eco-friendly, as they can be reused numerous times.
Gusseted Bags
Gusseted bags are versatile packaging solutions designed to accommodate a variety of items, from food to industrial products. These bags are characterized by their expandable sides or gussets, which allow them to expand and hold more contents than traditional flat bags. The gussets provide structural support and stability, making them ideal for packaging bulkier or irregularly shaped items. Gusseted bags are commonly used in industries such as agriculture, retail, and manufacturing, offering convenience and efficiency in storage and transportation.
Header Bags
Header bags are display bags with brand information at the top and a bag attached underneath for the product. They are clear poly bags such that the item on display can be easily seen but securely sealed at the top to prevent tampering. In most cases, header bags have a hole in the header such that they can be hung on a display rack. The printed, sealed top removes the need for a cardboard or paper attachment, which significantly reduces the cost of the bag.
Drawstring Bags
Poly drawstring bags are versatile and practical accessories that have become popular for a variety of uses. These lightweight bags are typically made from durable polyethylene material, making them both sturdy and water-resistant. Their drawstring closure allows for easy access and secure closure, making them ideal for carrying gym clothes, sports gear, or even groceries. They come in a wide range of colors and designs, making them a stylish choice for fashion-conscious individuals. Additionally, their affordability and eco-friendliness, as they are often reusable, contribute to their widespread appeal.
Chapter 4: Types of Poly Materials
The different types of poly materials allow producers to manufacture bags of varying thicknesses and endurance. Since the development of the first polymer over a hundred years ago, engineers and designers have continually developed new ways to combine the basic components to create stronger and more durable poly materials.
The different types of poly bags offer unique benefits and qualities that allow them to be adaptable to specific applications. The manufacture of poly bags includes the use of five types of plastic ideal for the production of plastic bags.
HDPE is the most used poly material for the manufacture of poly bags and is composed of a linear polymer with minimal branches. The chemical structure of HDPE is what creates its high density; HDPE is lightweight, sturdy, and nearly opaque. The resilience of HDPE gives it the ability to hold heavy loads without breaking. The image below is the recycling symbol for HDPE; it indicates the type of plastic and that it is easy to recycle.
Low Density Polyethylene (LDPE)
LDPE is the polymerization of ethylene; it was completed in 1933 and found practical use in 1939. The polymer is short with branched chains resulting in a plastic film that is light weight with low tensile strength. It has a low melting point, making it ideal for bags to be heat sealed. LDPE is a type of polymer that is found in food packaging and coverings for clothes from dry cleaners.
Linear Low Density Polyethylene (LLDPE)
LLDPE is a blended form of LDPE to make a more flexible, softer, and pliable plastic with greater tensile strength and formability. A unique feature of LLDPE is its ability to withstand heavy impact and stress without puncturing or tearing. Its molecules hold firmly together, which allows LLDPE to stretch. Common thicknesses for LLDPE are between 0.5 mil to 40 mil.
The gauge and clarity of LLDPE is better than HDPE, and LLDPE has HDPE’s strength. This makes LLDPE a cost effective replacement for LDPE.
Medium Density Polyethylene (MDPE)
MDPE was perfected to be a variation between HDPE and LDPE. The density of MDPE is not sufficient for the storage of bulk materials. It has low tolerance to chemical exposure and low tensile strength, but easily stretches. It is stronger than LDPE and has a tighter cell structure, which makes it more tear and puncture resistant than LDPE. Producers usually blend it with LLDPE or LDPE to create a stronger and more resilient material.
MDPE is produced using either a chromium-silica, Ziegler-Natta, or metallocene catalyst to give it shock and drop resistance. The unique properties of MDPE have made it useful for several types of poly bags.
Polypropylene is a thermoplastic made from propylene monomers that was first introduced in 1951. It rapidly gained popularity as a material for the production of commercial products and is one of the most popular poly bag materials due to its resistance to chemicals and high melting point. The material of PP is non-breathable, which gives it a long shelf life and a safe means for storing food.
The popular use of polypropylene is also due to its ability to retain its shape after torsion, bending, and flexing. Its resistance to electricity makes it an ideal material for the storage of electrical components.
Polyolefin
Polyolefins are polymers made from olefin monomers. They are a popular packing material since they can be easily molded and reshaped multiple times by being heated, molded, and cooled. Polyolefin plastics are durable, flexible, and resistant to chemicals, solvents, and moisture.
In the case of poly bags, polyolefin is often used as shrink wrap. Common examples of polyolefins are polyethylene, polypropylene, and polybutene.
Recycled Plastic
With the rising concern for the environment and the bad name that has been given to poly bags, manufacturers have developed sophisticated methods to recycle plastic bags such that they can be used to produce new bags or other products. To remove contaminants and impurities, the bags are melted and dried to form the pellet-like material that is used in the extruding process.
To ensure purity, the pellets undergo a set of purification processes before being sent to the extruder for reprocessing. Manufacturers have perfected and improved this process such that any plastic bag can be used and reprocessed multiple times, creating substantial savings for the environment.
Chapter 5: How Poly Bags Are Recycled
The recycling of poly bags is a complicated process that is continually being perfected as the need to improve its efficiency and effectiveness continues to grow. Though not all types of poly bags can be recycled, many that are commonly used are chosen for that ability and purpose.
The key to recycling plastic bags, a practice manufacturers strongly support, is the proper disposal of them. As concern for the environment has grown, behaviors such as throwing plastic bags from a vehicle or leaving them at a campsite has drastically declined. Fines and penalties for improper disposal and awareness on part of the public has minimized the problem.
There are a variety of methods that producers use to recycle plastic bags. Each process is unique to the manufacturer and is customized to fit their operation. Regardless of the differences between processors, there are certain generic steps that are common to all.
Examination
The recycling process begins with the collection of poly bags from various sources, such as households, stores, and recycling centers. Before recycling, these bags undergo an initial examination. During this step, contaminants like labels, stickers, and other non-polyethylene materials are removed manually or through automated sorting systems. It is crucial to ensure that only clean and pure polyethylene bags are processed to avoid impurities in the final recycled product.
Washing
Once the bags have been separated from contaminants, they are thoroughly cleaned to remove any residual dirt, debris, or food residue. This cleaning process typically involves soaking the bags in water and using mechanical agitation to scrub away impurities. Detergents or other cleaning agents may be used to assist in the cleaning process.
Melting
Cleaned and sorted poly bags are then heated in a controlled environment to melt the plastic. Polyethylene has a relatively low melting point, making it suitable for this step. The melted plastic is transformed into a thick, viscous liquid.
Drying
After melting, the molten plastic undergoes a drying process to remove any moisture content. Excess moisture can lead to defects in the recycled material, so it is essential to ensure that the plastic is completely dry before further processing.
Chopping
The dried, molten polyethylene is then cut into small pellets or granules using specialized cutting equipment. These smaller pieces are easier to handle and facilitate the subsequent extrusion process. The size of the pellets can vary depending on the intended application of the recycled plastic.
Extruding
In this step, the chopped polyethylene pellets are melted once again and then forced through an extruder. An extruder is a machine that uses heat and pressure to shape the molten plastic into a uniform, continuous profile or shape. In the case of poly bags, this process typically results in the creation of plastic sheets or strands.
Formation of Resin
The extruded polyethylene is now in the form of resin, which can be used to manufacture various products. Depending on the intended application, the recycled resin may undergo additional processing, such as blending with virgin polyethylene or other additives to achieve specific properties like strength, color, or flexibility.
Once the recycled resin is ready, it can be used in a variety of applications, such as the production of new poly bags, plastic lumber, plastic containers, and more. Recycling poly bags not only conserves valuable resources but also helps reduce the environmental impact associated with the production and disposal of plastic products.
The complete process can be seen in the diagram below.
Chapter Six: Top Five Poly Bag Manufacturing Machines
Rutan Poly Industries, Inc.
Rutan Poly Industries produces all sizes and shapes of poly bags using a wide selection of plastic materials. The company produces bags with printing, clear, and custom designs for all sizes of businesses. Rutan is known in the industry as a company that can produce custom bags to fit the needs of unusual and unique applications. The company’s custom bags include custom seal bags, side weld bags, wicket bags, and watertight bags using LDPE and LLDPE poly that is double or single wound and tinted or colored. Rutan works with their customers to provide a bag that perfectly fits the customer’s needs.
International Plastics
International Plastics believes that custom packaging is a perfect solution to promoting and displaying a product. The company listens to the requirements of customers to develop solutions that can make a product stand out and be noticed. International Plastics will continue to work with their customers until the customer feels they have the right packaging to display their product. The company produces gusseted bags in gauges of plastic that range from 0.0004 inch up to 0.012 inch with roll diameters of 7 inches up to 24 inches. International Plastics is proud to take on any challenge to prove how diverse and capable they are.
Four Star Plastics
Four Star Plastics produces high quality plastic bags with a company’s logo printed on the bag or a message for customers. The company works with any industry, regardless of products or packaging needs. Four Star has thousands of designs, styles, and sizes of plastic bags, tubing, and plastic sheeting with film in 14 printable colors. The choice of colors from Four Star is endless and includes various pantones that can highlight a company’s logo. Four Star Plastics is proud of its ability to deliver on time and provide the highest quality packaging products.
Dana Poly
Dana Poly manufactures blown film and poly bags for custom packaging solutions to protect, define, and enhance a customer’s products. The company works with customers to provide cost effective solutions of the highest quality. The poly products provided by Dana Poly include antistatic bags, biohazard bags, custom designed bags, high quality printed poly bags, and furniture cover bags. The company offers hanging gusseted poly bags for door hangers and perforated wicket poly bags that tear off easily.
Dana Poly prides itself on having a plastic bag solution to fit the needs of every customer regardless of how unique and unusual.
APAC Manufacturing
APAC offers a wide assortment of custom poly bags and plastic film that include plastic liners and poly bags for packaging as well as pallet covers and CF sheeting. The company prides itself on manufacturing high quality poly bags that will not tear or rip and is committed to providing a plastic poly bag that fits a customer’s requirements. APAC professionals work with customers to get a clear picture of the customer’s business and the type of durable packaging they need. Using expertise, experience, and a vast fund of knowledge, APAC manufactures poly bags that meet and exceed customer demands. The key focus of APAC is providing exceptional customer service regardless of the application or demands.
Chapter 7: Poly Bag Regulations and Standards
Due to the visibility and use of poly bags, there has been a great deal of attention focused on their use, disposal, and recycling. Regulations for poly bags have been adopted by individual states in the U.S., the United States Federal Government, and legislated international codes. All of the various restrictions are designed to control their environmental impact.
In addition to ecological regulations, standards have been established by the Federal Food and Drug Administration (FDA) and the United States Department of Agriculture (USDA). These organizations monitor materials and items that come into contact with the public such as food, medicines, medical instruments, and pharmaceutical products.
Federal Drug and Food Administration (FDA)
The FDA standards are the same standards that are used by the United States Department of Agriculture (USDA). The standards for poly bags reference the raw materials used to produce the bags, which are required to be food grade. In this context, food grade refers to materials that have not been previously used and are not reprocessed.
The regulations further describe and identify the various types of polymer materials that are acceptable. The list encompasses hundreds of different bags with specific descriptions of requirements.
State Regulations
Individual states have legislated requirements for plastic bags, with three states and the District of Columbia having legislation forbidding their use. The control of poly bag distribution and use has also been legislated by individual municipalities and counties, as can be seen in the diagram below. The map also identifies the states and their status regarding Poly Bags.The purpose of banning and laws regarding the use of poly bags is in reference to bags from grocery store checkout and other single use bags.
Internationally
European Union (EU) – The EU has several directives regarding poly bags and control of their use. The directives include 90/128/EEC, 92/39/EEC, 93/9/EEC, 95/3/EEC and 96/11/EC, Section A, to name a few. These regulations are in regard to the use of poly bags for storing and displaying food as well as bags that are permissible for medical use.
Great Britain – Great Britain has enacted legislation that is similar to that of the EU regarding what types of poly bags are permitted for use with food, pharmaceuticals, and medical equipment.
Though poly bags have been viewed negatively, much of the information regarding them is out of date. Present day producers work diligently to produce poly bags that meet the necessary environment and ecological standards. They are very aware of the impression poly bags have and work tirelessly to improve their products to ensure they are compliant.
Conclusion
A poly bag is a common shipping and packaging resource made of polymer material that is exceptionally durable, pliable, and customizable to fit any application.
Though polyethylene was introduced during the first industrial revolution, it wasn‘t until the 1950s that it was turned into the poly bags we see today.
The production of poly bags involves highly technical and scientifically engineered processes that are precisely planned to ensure high quality results.
The many options and designs for plastic bags has made them an essential part of society.
The different types of poly materials allow producers to manufacture bags of varying thicknesses and endurance.
Leading Manufacturers and Suppliers
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