How to Build a Scalable Tape System for Fast-Growing Warehouses

An increase in warehouse activity usually ushers in new challenges. More orders mean you have to hire more staff and beat tighter schedules, leading to a perfect recipe for packing errors.

Something as simple as tape is easy to overlook in the rush to keep up. Yet, the right tape system can improve safety and support long-term efficiency.

This article shows how you can build a future-ready tape system using solutions from Tape Jungle. Our custom tape options and bulk orders designed for busy operations prove Tape Jungle is your reliable partner in growth. We can help you keep pace without sacrificing consistency.

Start With the Core: Optimizing Your Shipping Tape Setup

Building a scalable tape solution is not as tedious since one of the starting points goes straight to the heart of the matter - installing the right shipping tape setup.

Match Tape Type to Throughput

Choose an adhesive tape that's strong enough and works well with the intended surface you will apply it to. For instance, a busy warehouse with heavy shipments will need stronger tape, while lighter orders or fragile items may work better with a gentler option. A plane needs industrial tape to withstand heat reflection or create a vapor barrier.

Here are examples of different types of tape suited to various conditions:

• Acrylic tape: Provides a strong bond and works well in extreme temperatures. You can use it in cold storage or vehicle trim.
• Hot melt: May not work in such extreme temperatures as acrylic tape, but it has higher tensile strength to handle heavier loads.
• Gummed paper tape (water-activated tape): It bonds firmly once moistened and forms a seal that is hard to tamper with.

Level Up With Custom Packing Tape

Custom-printed tape makes it easier to track batches in storage. This is important in the food industry as printing details such as your EC number helps traceability. Customized tapes also build your brand by keeping your logo visible and showing customers you value quality.

Printed messages like "Fragile" guide handling to ensure orders arrive in great condition. The tape also boosts security by deterring tampering, while helping quickly identify outgoing shipments.

Tape Jungle's interactive customizer lets you design professional packing tape. The tool guides you through each step, allowing you to add text, logos, colors, or artwork from our database to match your brand.

Use Machines and Dispensers for Efficiency

You should consider introducing tape equipment compatible with your workflow. Such dispensing systems could be:

• Manual
• Automatic
• Water-activated

Whatever dispenser type you settle on will speed up packing and reduce labor compared to traditional methods. Automatic paper tape dispensers are much faster and more efficient.

They also cut down on waste. Cutting warehouse tape by hand often causes folds or loss of stickiness, which leads to waste. Dispensers apply tape evenly and consistently to ensure proper sealing of boxes every time.

Zone Your Space With Floor Marking and Color-Coded Tape

It takes time to train new hires to master the workplace layout, especially considering the layout may change to cater to seasonal demands. This can eat away at valuable working hours, but using color-coded tape and floor markings can help.

Use Floor Marking Tape To Define Work Zones

These are an effective way to guide movement and improve safety in busy workspaces, according to OSHA guidelines.

Use floor marking tape to plot pedestrian paths that keep people away from forklifts and dangerous equipment, easily telling employees where to walk, stand, or avoid. It also serves as a warning around loading docks, exposed edges, and high-traffic areas where you need extra caution.

Glow-in-the-dark tape is handy in low-light conditions as it helps employees find exits quickly. Floor marking can also section off specific areas for storage.

Implement Color-Coding To Boost Team Efficiency

Color makes information easier to process at a glance. Use it to show priority and draw attention to errors that text alone might miss. It also speeds up learning for trainees since color helps the brain spot patterns and retain them faster.

You can use different colored vinyl or duct tape to help new hires identify process zones, such as:

• Returns
• Outbound
• Fragile
• Expedited

Streamline Pick and Pack Processes Using Visual Tape Systems

Packaging boxes tend to come in the same brown color, which is a nightmare to sort out without proper systems. But using visual tape helps streamline the entire process.

Create Visual Cues With Tape for Faster Sorting

One of the easiest ways to simplify operations is to use colored tape to mark specific areas. For example, use colored tape for shelf and rack tagging, bin labelling, or pallet labelling to guide order packers.

When every box looks the same in a busy warehouse, sorting them can waste time. Custom colored packaging tape solves this by distinguishing boxes clearly. They also encourage the standardization of the sorting setup across your warehouse organization.

Use ATG Tape for Mounting Instructions or Temporary Signage

ATG (Adhesive Transfer Gun) is an acrylic transfer tape. It uses a thin layer of adhesive that bonds directly to a surface without any backing. Unlike regular tape, ATG tape leaves no residue behind - ideal for projects where neatness is important.

ATG tape applies easily and creates a strong hold, whether for temporary or permanent mounting of job aids, zone maps, or safety instructions.

Primary uses of ATG include:

• Mounting photos and posters: ATG tape creates clean lines that make projects look polished.
• Framing and matting: The tape provides strong adhesion without curling or warping and keeps artwork free of visible adhesive lines.
• Packaging: ATG tape seals cartons securely with a tamper-evident bond that holds up during shipping and handling.

Build in Flexibility for Layout Changes

The layout of your storage facility won't always stay the same, as you must adjust inventory numbers to fit peak season. This will require you to change labels and retrain staff to minimize delays.

Use Repositionable or Easy-Lift Tape for Agile Warehousing

If you intend to change inventory locations frequently, you need an adhesive solution that you can move around cleanly. That's where easy-lift tape comes in. Repositionable adhesive lets you apply and remove labels multiple times without losing bonding strength.

The special formula in easy-lift tape allows you to shift labels to different locations fast. This is the perfect solution during seasons known for high-volume stock movement.

Modular Tape Systems Simplify Training and Turnover

Use a standardized tape color system to direct traffic for new employees. Since color makes it easier to remember, it will make onboarding incoming staff easier. Use the color system to label everything from walkthroughs to pallets and shelves.

A standardized tape color system is most effective in guiding both vehicle and foot traffic around your business, eliminating the need for verbal walkthroughs. It helps streamline onboarding, even in high-turnover situations.

Plan for Growth: Inventory, Ordering, and Replenishment

Sudden growth can catch you off guard, leaving you with angry customers due to delivery delays. The only way to stay ahead of the curve is to plan how to maintain inventory and replenish supplies.

Forecasting and Bulk Ordering

Keeping accurate inventory data is essential when preparing for peak season. Without it, you risk delaying shipments and frustrating customers with backorders.

Reviewing inventory data helps you spot when order volumes spike, such as during holidays. A pre-holiday inventory audit gives you a clear view of current stock and improves your ability to forecast demand.

This will help you order enough stock to sail through the busy season. Keep in mind that bulk ordering lets you benefit from economies of scale, which lowers the cost per unit. It also helps maintain a steady supply of essential items and ensures consistency in the ordered products.

Simplified Reordering for Custom Tape

You can order custom-designed tape from Tape Jungle with a fast turnaround. Tape Jungle ships 95% of its orders in two business days. Your design files remain stored in your account once you place your first order, making reorders quick and pain-free. If you are unsure about the best design, the team at Tape Jungle can guide you.

For urgent order needs, Tape Jungle offers a Rush Order option. Selecting this during checkout moves your order to the front of the queue and cuts production time significantly. This service applies to eligible products that meet approval. Visit the Rush Order page for more details on turnaround times or eligibility.

Bonus: Sustainable Tape Choices That Scale With You

Seventy-eight percent of consumers view sustainability as important, and 84% say poor environmental practices can turn them away from a brand.

Taking care of the environment is a top priority. If your brand has environmental consciousness, Tape Jungle has solutions you'll appreciate.

Upgrade to Gummed Paper Tape

Gummed tape offers several advantages worth considering:

• Most options are fully biodegradable and recyclable, making them eco-friendly.
• It's compatible with machine dispensers and automation tools.
• The tape requires a dispenser that moistens and cuts it automatically. This reduces waste and speeds up your packing process.
• Paper tape also provides a tamper-evident seal that strengthens security during shipping.
• It can withstand hot and cold temperatures without losing adhesion (unlike plastic), ensuring the seal stays intact even in changing conditions.

Tape Jungle Offers Eco and Performance Options

You have a choice of eco-friendly tape that delivers the strength and reliability you need while giving you peace of mind when it is time to dispose of it. These tapes prove that Tape Jungle balances performance with responsibility.

Tape Jungle offers a range of eco-friendly paper tapes, such as:

• Bleached flat-back paper tape
• Blue painters tape
• Natural kraft-reinforced water-activated carton sealing tape

For companies aiming to cut waste and build greener operations, Tape Jungle's line of custom-printed gummed tape is the smart choice. It's eco-friendly and ensures you don't pass high packaging costs on to your customers, all while being delivered on time.

Build Your Custom Packing Tape Now

A smart tape system goes deeper than just adhesives. It's a tool that helps scale your operations with greater clarity, safety, and speed. A well-thought-out tape system boosts traceability, improves workflow efficiency, and cuts down costs. The right tape choices will keep your warehouse running without a hitch, even during peak demand.

Explore Tape Jungle's full catalog of tapes or connect with our team to find the best fit for your needs. Contact us today for help in building a scalable tape system.