The usual objection to switching from plastic to paper packaging tape is performance: will it hold, will it slow the line, will it cost more. Those concerns are reasonable, and the honest answer is that paper tape matches or beats plastic on some measures and falls short on others. This is where the trade-offs actually land.
Key points
- On sealing paper cartons, water activated paper tape is stronger than plastic tape because it bonds into the board.
- It is faster and more consistent on a dispenser once the bench is set up, and it uses less tape per carton.
- It costs more per metre, needs a dispenser and water, and does not work on plastic, coated or frozen surfaces.
- For most volume carton-sealing operations the trade is net positive; for low volume or non-paper packaging it is not.
Where paper tape wins
- Seal strength on cartons. In an independent test, cartons sealed with water activated tape failed at about 60 pounds of force versus about 17 pounds for pressure-sensitive tape, because the paper tape bonds into the fibres rather than sitting on the surface.
- Tape used per carton. One H-pattern strip usually seals a carton, where plastic tape often gets two or three passes for the same security. The average carton uses less tape.
- Pack-bench speed and consistency. On a dispenser, carton-sealing productivity in the same test was about 21% higher than a hand gun with plastic tape, and every seal is the same length and pressure.
- Recycled and low-grade board. The fibre bond grips dusty, recycled liner where a surface adhesive struggles.
- Recyclability and tamper evidence. The carton recycles whole, and any opening attempt tears the board.
Where paper tape gives ground
- Unit cost. Paper gummed tape costs more per metre than acrylic or hot-melt BOPP. Lower tape use per carton offsets some of it, and most volume operations find total landed cost close to neutral, but the sticker price is higher.
- Equipment. It needs a dispenser and a water supply. Plastic tape needs only a hand gun. Below roughly 50 cartons a day the dispenser does not pay back.
- Surfaces. No bond to poly mailers, laminated or waxed board, plastic or metal. Plastic tape is more forgiving here.
- Temperature and moisture. Cold, frozen and wet conditions interfere with the starch adhesive. Acrylic BOPP holds a wide temperature range.
- Setup period. The first week is slower while packers learn the technique and the water level is dialled in.
How to decide
Paper tape is the right trade when you seal paper cartons in volume, ship heavy or hard-handled goods, want the carton to recycle whole, or use recycled board. It is the wrong trade when you ship mostly poly mailers, seal a handful of parcels a day, run a cold chain, or use coated cartons. Many operations run paper on the carton line and keep a roll of plastic for mailers and one-offs. The full picture is in the water activated tape guide and the box tape comparison.
Where Carewell fits
Carewell Group supplies water activated and reinforced gummed paper tape, plastic carton tapes, and dispensers, so we can be honest about which fits your line rather than selling one answer. Carewell can meet all your packaging needs in one place. Talk to our team and we will work to your required minimum order quantity. Request a quote and samples or call +61 (02) 8760 1491.
Frequently asked questions
Is paper tape actually as strong as plastic tape?
On paper cartons, stronger. It bonds into the board, so one strip holds where plastic tape needs multiple passes. On non-paper surfaces it does not work at all.
Will paper tape slow down my pack bench?
For the first week, while packers learn it. After that, on a dispenser, it is faster and more consistent than a hand gun with plastic tape.
Does paper tape cost more?
More per metre. You use less per carton, so most volume operations find total cost close to neutral once tape use and pack speed are counted.
When is plastic tape the better choice?
Poly mailers, very low volume, cold chain, coated or waxed cartons, and long outdoor storage.
Can I use both?
Yes, and many operations do: paper on the carton line, plastic for mailers and one-offs.
Written by Alif Vasaya, digital and content strategy, Carewell Group. Carewell Group is an Australian packaging, food packaging, tape, industrial safety and 3PL supplier serving all of Australia. Last updated 10 September 2026.