Common Packaging Challenges in Produce & Floral Operations

 

Whether you’re packaging herbs, leafy greens, flowers, bunching vegetables, berries, or other fresh products, many operations encounter the same challenges:

• Applying labels consistently and accurately
• Meeting retailer and traceability requirements
• Handling labor-intensive packaging tasks
• Maintaining product presentation through distribution
• Improving production speeds during peak harvest seasons
• Creating consistent package seals and closures

The good news is that many of these challenges can be addressed with simple automation solutions that deliver immediate operational benefits.

 

Labeling Solutions for Traceability, Branding, and Compliance 

 

Labeling has become increasingly important throughout the produce and floral supply chain. Product identification, PLU labels, barcode tracking, country-of-origin information, branding, and retail compliance all require accurate and consistent label placement.

With Tach-It’s expanded capabilities, customers can now source both labeling equipment and labels from a single supplier, simplifying procurement and ensuring compatibility between labels and equipment. Whether you’re applying produce labels, package labels, barcodes, or branded retail labels, Tach-It can help provide a complete labeling solution.

 

Mini-Con T Labeling System

 

For operations looking to automate label application, the Mini-Con T provides a compact, reliable solution for applying pressure-sensitive labels to a variety of packaging formats. Its tabletop footprint makes it ideal for growers, packers, and shippers seeking automation without dedicating significant floor space.

 

BL-1 Label Applicator & AP65 Applicator

 

Hand-applied labeling remains a necessity for many produce and floral operations. The BL-1 handheld label applicator is perfect for applying PLU labels. AP65 applicators provide fast, accurate label placement on:

• Produce containers
• Clamshells
• Bags
• Floral packaging
• Cartons and shipping cases

The result is improved consistency, reduced application time, and a more professional finished package.

 

PDL 12 Label Dispenser

 

Even small improvements can create significant productivity gains. The PDL12 Label Dispenser automatically presents labels for easy removal, helping operators apply labels faster while reducing waste, improving efficiency, and maintaining steady workflow during peak production periods.

 

Faster Produce, Floral, and Agricultural Tying

 

Many agricultural products require support, bundling, or tying throughout the growing and packaging process. Tomatoes, grapes, cucumbers, peppers, vine crops, herbs, flowers, and other specialty crops often rely on manual tying methods that can be time-consuming and inconsistent.

 

3510A Handheld Tyer

 

Designed for agricultural staking and tying applications, the 3510A Handheld Tyer quickly secures plants, vines, stems, and bundled products with a gentle tie that helps protect delicate crops.

Unlike manual tying methods, the 3510A creates consistent ties that hold plants securely without damaging stems or restricting growth, making it an ideal solution for greenhouses, nurseries, vineyards, floral operations, and produce growers.

Key benefits:

• Gentle on stems, vines, flowers, and plants
• Supports healthy plant growth
• Faster and more consistent than manual tying
• Reduces labor requirements
• Lightweight and easy to operate

 

Reliable Bag Sealing for Fresh Products

 

Fresh produce packaging often depends on secure, consistent closures to protect product quality during transportation and display.

3235 Bag Sealer

 

The 3235 Bag Sealer offers an efficient solution for sealing produce bags used for items such as:

• Apples
• Carrots
• Citrus
• Bulk vegetable packaging
• Floral sleeves and protective packaging

 

By creating consistent seals, operations can improve package presentation while reducing variation associated with manual sealing methods.

A Complete Produce & Floral Packaging Partner 

 

Beyond packaging efficiency, produce and floral businesses are increasingly looking for partners who can provide complete solutions. By combining equipment, consumables, and application expertise, Tach-It helps growers, packers, and shippers streamline sourcing while improving consistency across their operations.

From labels and label applicators to tying and sealing equipment, customers can access practical automation solutions backed by knowledgeable support. Having a single source for both equipment and consumables helps simplify operations while ensuring products work seamlessly together.

 

Why Entry-Level Automation Makes Sense 

 

A common misconception is that automation requires a significant investment in large-scale equipment. In reality, many produce and floral businesses achieve meaningful productivity gains through targeted, entry-level automation solutions.

The advantages include:

• Lower initial investment
• Faster implementation
• Small footprint & small batch runs
• Minimal training requirements
• Improved labor efficiency
• Greater packaging consistency
• Scalable growth path

As production volumes increase, these solutions often serve as the foundation for broader automation initiatives.

 

Ready to Explore Automation? 

If you’re looking for ways to improve labeling, plant tying, bundling, sealing, or packaging efficiency in your produce or floral operation, Tach-It offers a wide range of Entry Level Automation™ solutions designed to deliver immediate results while supporting long-term growth.

From supplying labels and label application equipment to specialized agricultural tying and bag sealing solutions, Tach-It helps growers, packers, shippers, and distributors automate with confidence.

What is an Impulse Sealer?

 

An impulse sealer is a type of heat sealing machine that uses a brief burst of electrical energy to heat a sealing element. When the sealing arm closes, heat is generated only during the sealing cycle, melting the layers of plastic together to create a permanent seal.

Unlike constant heat sealers, impulse sealers remain cool between cycles. This makes them energy-efficient, safer to operate, and suitable for many common thermoplastic bag materials.

Common materials that can often be sealed with impulse sealing technology include:

• Polyethylene (PE)
• Polypropylene (PP)
• Polyolefin
• Shrink bags
• Many laminated plastic materials

 

When is an Airtight Seal Required? 

 

Not every package requires a hermetic seal, but many products benefit from creating a strong barrier against air, moisture, dust, or contaminants.

 

Food Packaging

Airtight seals help preserve product freshness and protect products from outside contamination. Bakeries, snack manufacturers, coffee roasters, and food processors frequently use impulse sealers to secure packaged goods.

 

Medical and Laboratory Products

Medical supplies and test components often require reliable package closure to maintain product integrity during storage and transportation.

 

Industrial Components

Small parts, hardware, electronics, and sensitive materials can be protected from moisture, dust, and handling damage with properly sealed bags.

 

Retail Packaging

A clean, professional seal improves package appearance and helps prevent tampering during shipment and display.

 

Benefits of Impulse Sealing Technology

 

Impulse sealers remain one of the most popular bag sealing solutions because they offer several advantages:

 

Safer Than Heat Sealing

Heat sealers require that a temperature is set on the machine and that the sealing bars are maintained at that temperature. This can cause burns to the operator. With an impulse sealer, there is only a brief burst of heat and much less chance of operator injury.

 

Energy Efficient

Because heat is generated only during the sealing cycle, impulse sealers consume less energy than continuous heat sealing systems.

 

Easy to Operate

Most machines require only a simple adjustment of the sealing timer based on the bag material and thickness. Once set, operators can consistently produce clean seals.

 

Reliable Seal Quality

A properly-configured impulse sealer can create strong, repeatable seals that improve packaging consistency and reduce rework.

 

Affordable Entry into Packaging Automation

For many operations, impulse sealers offer an economical way to improve packaging quality without investing in a fully automated packaging line.

 

How to Choose the Right Impulse Sealer

 

1. Bag Material

 

Different plastics require different sealing temperatures and dwell times.

Thin polyethylene bags seal quickly and easily. Heavier laminates or specialty materials may require broader seals, longer sealing times, or dual-heating systems.

When determining equipment requirements, always verify:

• Material type
• Material thickness
• Number of layers being sealed
• The thicker the material, the more sealing power is generally required.

 

2. Material Thickness 

 

One of the most important specifications is bag thickness, typically measured in mils.

As bag thickness increases, stronger sealing systems become necessary.

For example:

• Light-duty tabletop sealers may handle materials up to 4-6 mils.
• Wide-seal models can handle materials up to 6-8 mils.
• Heavy-duty dual-heating systems can seal materials up to 20 mils thick.

Choosing a sealer that matches your bag thickness is essential for achieving consistent airtight seals.

 

3. Seal Width

 

Seal width affects both package appearance and seal strength.

A standard 2 mm seal is sufficient for many everyday packaging applications. Wider 5 mm seals offer greater strength and durability, making them popular for heavier bags and demanding environments.

 

3. Production Volume

 

The number of bags sealed per day often determines which machine type is most appropriate.

A small operation sealing dozens of bags each day has vastly different needs than a production facility sealing thousands.

 

Which Tach-It Impulse Sealer is Right for You?

 

HJ and HJC Series: Best for Low-to-Medium Volume Packaging

 

The Tach-It HJ and HJC Series consists of compact tabletop impulse sealers designed for easy operation and minimal footprint. Models are available with seal lengths from 4 to 16 inches and seal widths of either 2 mm or 5 mm. The HJC models also include an integrated cutter that trims excess bag material above the seal for a cleaner finished package.

Best for:

• Shipping departments
• Retail packaging
• Small food production operations
• General-purpose bag sealing

 

HI Series: Best for Higher Production Environments

 

The Tach-It HI Series features self-standing foot-operated sealers that free the operator’s hands for positioning product and bags. Available in 12-, 18-, and 24-inch seal lengths, these machines are designed for increased productivity while preserving valuable workbench space.

Best for:

• Manufacturing facilities
• Distribution centers
• Food processors
• Higher-volume packaging operations

 

HIW Series: Best for Heavyweight Bags

 

When sealing thick or heavy-duty materials, the HIW Series offers a significant advantage. Unlike standard impulse sealers that heat from one side, the HIW machines apply heat from both the upper and lower jaws, enabling sealing of materials up to 20 mil thick.

Best for:

• Heavy industrial packaging
• Thick poly bags
• Multi-layer materials
• Bulk product packaging

 

HA Series: Best for Consistent High-Volume Sealing

 

The HA Series combines semi-automatic operation with a preset dwell timer and electromagnetic pressure system. This design helps eliminate operator variability, producing highly consistent seals during continuous production. Models are available in seal lengths from 14 to 24 inches and widths of 2 mm or 5 mm.

Best for:

• Repetitive production environments
• High-volume bag sealing
• Facilities requiring seal consistency
• Quality-sensitive packaging operations

 

 

Frequently Asked Questions? 

 

What materials can be sealed with an impulse sealer?

Impulse sealers are commonly used with polyethylene, polypropylene, polyolefin, and many other thermoplastic materials.

 

Can impulse sealers create airtight seals?

Yes. When properly matched to the bag material and thickness, impulse sealers create strong airtight seals that help protect products from moisture, contaminants, and air intrusion.

 

What is the difference between a 2 mm and 5 mm seal?

A 5 mm seal provides a larger sealing surface and generally offers greater seal strength, making it a good choice for heavier bags and demanding applications.

 

Do thicker bags require a different type of sealer?

Often, yes. As bag thickness increases, more sealing energy and sometimes dual-sided heating are required. Heavyweight materials may be better suited for machines such as the Tach-It HIW Series.

 

Selecting the Right Sealer Starts with the Application

 

Choosing the right impulse sealer is about more than seal length alone. The ideal machine depends on your bag material, film thickness, required seal strength, and production volume.

For occasional sealing needs, a tabletop unit may be the perfect solution. For higher throughput operations or heavier materials, foot-operated and semi-automatic models can improve productivity while delivering stronger, more consistent results.

By understanding the fundamentals of impulse sealing technology, businesses can confidently select equipment that protects their products, improves package quality, and supports efficient packaging operations.

 

 

What is Water-Activated Tape (WAT)?

Unlike pressure-sensitive acrylic tape, water-activated tape uses a starch-based adhesive that remains dormant until water is applied.

Once moistened, the adhesive becomes activated and forms a strong bond with the corrugated carton surface. Rather than simply sticking to the box, the adhesive penetrates the fibers of the corrugated material and becomes part of the carton itself.

The result is a strong, permanent seal that is difficult to remove without visibly damaging the box.

 

Water-Activated Tape vs. Acrylic Tape

 

A simple way to understand the difference:

Acrylic tape sticks to the box. Water-activated tape bonds to the box.

Why Companies Choose Water-Activated Tape

 

Better Package Security

Because the adhesive bonds directly to the carton fibers, attempts to open the package leave visible evidence of tampering. This makes WAT a popular choice for e-commerce, industrial products, electronics, and other higher-value shipments.

 

Stronger Carton Seals

Reinforced water-activated tape often allows companies to securely seal cartons with a single strip down the center seam, even on heavier packages.

 

Improved Sustainability

Paper-based water-activated tape is generally recyclable along with corrugated cartons, reducing reliance on plastic packaging materials.

 

Enhanced Brand Presentation

Water-activated tape lays flat and creates a clean, professional appearance. Custom printing options can also transform shipping cartons into branded marketing assets.

 

Why Heated Water Matters

 

Many companies don’t realize that water temperature plays an important role in seal performance.

Warm water helps activate the starch-based adhesive faster, allowing it to penetrate carton fibers more effectively and create a stronger bond. It also improves performance in colder environments and helps speed up package processing in higher-volume operations.

This is where dispenser design matters.

 

The Tach-It Advantage

 

The Tach-It WAT-E and Tach-It WAT-J water-activated tape dispensers include heated water systems as a standard feature, helping deliver reliable tape activation and consistent carton seals.

This is particularly important because many competing dispensers offer heated water only as an optional upgrade.

 

 

Is Water Activated Tape Right for You?

Water-activated tape is an excellent choice if you:

• Ship high-value products
• Want better tamper protection
• Seal heavy cartons
• Support sustainability initiatives
• Want a cleaner, more professional package appearance

For many businesses, the investment pays for itself through stronger seals, greater package security, and a better customer experience.

Most packaging operations are not starting from scratch. They already have a process in place. Boxes are being formed, filled, sealed, and shipped every day. The challenge is not building a new system. It is improving what already exists.

That is where packaging stations come into focus.

Instead of investing in large, complex automation systems, many operations can significantly improve output by upgrading individual steps within their existing workflow. The right combination of equipment can reduce manual effort, improve consistency, and increase throughput without disrupting the entire operation.

 

What Defines an Effective Packaging Station

 

A packaging station is not just a table with tools. It is a sequence of steps that determines how efficiently products move from packing to shipping.

At a high level, most stations include:

• Product preparation or bagging
• Sealing or closing
• Labeling or identification
• Final carton sealing

When any one of these steps relies too heavily on manual processes, it slows down the entire workflow. Variability increases, output becomes inconsistent, and operators spend more time correcting errors.

Improving a packaging station means tightening control at each step without overcomplicating the process.

 

The Case for Incremental Automation

 

Full automation has its place, but it is not always the right starting point. For many businesses, especially those handling varied products or moderate volumes, flexibility matters more than full system integration.

Incremental automation focuses on upgrading key tasks with standalone or semi-automatic equipment. This approach allows operations to:

• Increase speed without redesigning the entire line
• Improve consistency across operators and shifts
• Reduce material waste and rework
• Maintain flexibility for different product types

It is a practical way to scale performance while keeping control over the process.

 

Building Blocks of a Better Packaging Station

 

Improving a station typically involves upgrading a few core functions. These upgrades work together to create a smoother, more controlled workflow.

 

Bag Opening and Preparation

For operations working with poly bags or wicketed bags, manual opening slows down filling and introduces inconsistency.

Bag opening machines streamline this step by presenting bags in a ready-to-fill position. This reduces handling time and keeps the process moving.

 

Bag Sealing

 

Once products are packed, sealing becomes critical for both protection and presentation.

Options include:

• Impulse sealers for airtight closures
• Twist tie machines for fast, repeatable bag closure
• Tape bag sealers for simple, reliable sealing

Each method serves a different purpose depending on the product and packaging requirements.

 

Labeling and Identification

 

Manual label placement is one of the most common sources of inconsistency in packaging.

Label applicators improve accuracy and speed by controlling placement. For more advanced needs, L-Clip systems can combine labeling and sealing into one step, adding both efficiency and security.

 

Carton Sealing

 

At the final stage, cartons need to be closed quickly and consistently.

Solutions range from:

• Manual and electric tape dispensers for controlled tape length
• Tape guns for quick taping
• L-Clip applicators for tamper-evident closures
• Case sealing systems for higher volume operations

The right choice depends on throughput requirements and the level of control needed.

 

Pre-Configured Solutions by Industry

 

Different industries have different packaging requirements. Tach-It recommends specific equipment combinations based on real-world applications.

 

Bakery and Food Packaging

 

Speed and freshness are the priority. Products need to be sealed quickly while maintaining presentation.

Typical setup:

• Wicketed bag opener
• Twist tie machine with ribbon
• Optional labeling for branding or compliance

This combination allows for fast packing while keeping products secure and visually consistent.

 

Medical and Pharmaceutical

 

Consistency and traceability are critical. Packaging must be precise and often tamper-evident.

Typical setup:

• Impulse sealer for airtight closure
• Label applicator for identification and compliance
• L-Clip applicator for secure carton sealing

This ensures controlled packaging with clear, verifiable sealing.

 

Manufacturing and Assembly

 

Durability and efficiency drive decisions in these environments.

Typical setup:

• Heavy duty tape dispenser or electric dispenser
• Bag sealing or bundling tools depending on product
• Labeling systems for tracking and identification

These tools reduce downtime and keep materials moving through the process.

 

E-commerce and Fulfillment

 

Throughput and flexibility are key. Operations often handle a wide range of products and packaging types.

Typical setup:

• Definite length tape dispenser for consistent sealing
• L-Clip applicator for fast carton closure
• Label applicator for shipping and tracking

This setup helps maintain speed while ensuring consistent packaging across orders.

 

Why the Right Combination Matters

 

Individual tools improve specific tasks, but the real impact comes from how they work together.

A well-designed packaging station:

• Reduces unnecessary motion for operators
• Eliminates bottlenecks between steps
• Improves overall workflow efficiency
• Delivers consistent results from start to finish

Rather than relying on one piece of equipment, it is the combination that creates a measurable difference.

 

A Practical Path Forward

 

Upgrading a packaging station does not require a full system overhaul. In many cases, replacing or adding one or two key pieces of equipment can significantly improve performance.

The goal is not to automate everything at once. It is to identify where time is lost, where inconsistencies occur, and where simple solutions can make the biggest impact.

 

The Bottom Line

 

Packaging stations are where efficiency is either gained or lost. By focusing on the right combination of tools, businesses can improve output, reduce variability, and create a more controlled workflow without committing to large-scale automation.

Tach-It equipment is designed to support this approach. Each product fits into a larger process, allowing operations to build a system that works for their specific needs.

Packaging operations are always balancing speed, consistency, and cost. For many businesses, traditional carton sealing methods like hand taping or stapling introduce variability, slow down throughput, and create unnecessary material waste.

L-Clip applicators offer a different approach. Instead of relying on multiple steps or excess consumables, they apply a secure closure in one controlled motion. The result is a faster, more consistent process that improves both efficiency and presentation across the line.

 

What is an L-Clip Closure?

An L-Clip refers to the path a material follows when it is applied from the side of a box to either the top or bottom panel in one motion. This method creates a strong seal while also acting as a tamper-evident closure.

L-Clip systems can apply:

• Pressure-sensitive tape
• Labels
• Round wafer seals

Because the material wraps across two surfaces, it holds the carton closed while clearly showing if the package has been opened or altered.

 

How L-Clip Applicators Work

L-Clip machines are designed to simplify the sealing process for operators while maintaining consistent results.

In most applications, the process is straightforward:

1. The operator positions the carton against the applicator
2. The machine is activated through a pad, roller, or switch
3. The material is applied from the side across the edge to the top or bottom
4. The carton exits sealed and ready for the next step

There is no need for complicated setup, multiple passes, or manual alignment. The system controls placement and application every time.

 

Why Operations Move to L-Clip Systems

Many companies adopt L-Clip applicators when manual sealing begins to limit output or create inconsistencies. These systems bridge the gap between hand processes and full automation.

Key operational advantages:

Speed without complexity
L-Clip machines allow operators to seal cartons quickly with a simple motion. Some systems can process dozens of boxes per minute depending on the setup.

Consistent placement
Every application follows the same path and position, reducing variation between operators and shifts.

Tamper-evident sealing
Because the closure crosses multiple panels, it is immediately visible if a carton has been opened.

Reduced material usage
Compared to excessive taping, L-Clip application uses only the material needed for the seal.

Minimal training required
Operators can learn the process quickly, which helps reduce onboarding time and operational errors.

 

Where L-Clip Applicators Are Used

L-Clip systems are used across a wide range of industries where secure and consistent carton closure matters.

Common applications include:

• Pharmaceutical and medical packaging
• Food and bakery cartons
• Retail and consumer goods
• E-commerce and fulfillment operations
• Industrial packaging environments

In each of these settings, the need is the same: close cartons quickly, securely, and consistently without slowing down production.

 

Equipment Options for Different Operations

One of the strengths of L-Clip systems is their flexibility. Tach-It offers a range of machines designed to fit different production environments.

Tabletop L-Clip applicators

Ideal for smaller operations or workstations where space is limited and flexibility is important. These systems provide controlled, repeatable application without requiring a full production line.

Inline and automated systems

Designed for higher volume environments, these machines integrate into conveyor systems and apply closures as cartons move through the line.

Mini Con L-Clip systems

Compact, programmable solutions that combine precision with a small footprint. These are well suited for operations that need consistent labeling or sealing with minimal space requirements.

 

Improving Efficiency Without Overcomplicating the Process

Not every operation needs full automation. In many cases, the goal is to improve output and consistency without adding unnecessary complexity.

L-Clip applicators provide that middle ground. They standardize the sealing process, reduce reliance on manual techniques, and help maintain a steady workflow without requiring large-scale system changes.

For growing operations, this can be a practical step forward that delivers immediate results.

 

The Bottom line

L-Clip applicators simplify carton closure by combining speed, consistency, and security into a single step. Whether using tape, labels, or wafer seals, they provide a reliable way to improve packaging performance across a wide range of applications.

If your operation is looking to reduce variability, increase throughput, or improve presentation, L-Clip systems offer a proven solution that fits into existing workflows.

 

Explore L-Clip Solutions from Tach-It by Bedford

Tach-It offers a full range of L-Clip applicators designed for real-world packaging environments. From compact tabletop units to automated systems, each solution is built to deliver consistent results and long-term reliability.

L-Clip Units for Taping:

• 6425 L-Clip Tape Applicator
• 6400 L-Clip Tape Applicator

L-Clip Units for Labeling:

• 6500 TL – L-Clip Label Applicator 
• 6510-TL – Label Applicator
• Mini Con L-80 – L-Clip Label Applicator
• Mini Con L-FB – L-Clip Label Applicator

Wafer Seals for L-Clip Label Applicators:

• 1 inch wafer seals
• 1.5 inch wafer seals

Bagging is one of those processes that looks simple until you try to scale it. At low volumes, manual bagging gets the job done. But as output increases, the small inefficiencies start to compound. Opening bags takes longer than expected. Operators work at different speeds. Closures vary. And before long, what should be a straightforward process becomes a source of lost time and inconsistent results.

At Tach-It, we don’t look at bagging as a single step. We look at it as a connected workflow that starts with how the bag is opened and ends with how it is sealed.

When each step is aligned, everything downstream improves.

 

The Hidden Cost of Manual Bagging

Most operations don’t notice bagging as a problem right away. It usually shows up indirectly.

You see it in:

• Slower than expected throughput
• Operators falling out of rhythm
• Inconsistent package appearance
• Increased labor to maintain output

 

The root issue is not one specific task. It is that each step—opening, filling, sealing—is being handled independently instead of as a system.

That lack of continuity creates friction. And friction is what slows production.

 

Step One: Stabilizing the Process with Bag Opening

Before anything is inserted into the bag, the process has already been defined. If the bag is difficult to open, inconsistent in position, or constantly shifting, everything that follows becomes harder. Operators compensate in different ways, which leads to variability in speed and handling.

This is where a wicketed bag opener changes the dynamic. Instead of manually separating and opening each bag, the machine presents it in a consistent, open position every time. The operator no longer has to “prepare” the bag. They can move directly into filling it.

The impact is immediate:

• The motion becomes repeatable
• The pace becomes steady
• The operator stays focused on the product, not the packaging

What seems like a small improvement at the start of the process ends up setting the tone for the entire workflow.

 

Filling Becomes Faster When Opening Is Controlled

Once the bag is consistently open and positioned, filling becomes a much more natural step. Operators are no longer adjusting their grip, repositioning the bag, or pausing to reopen it. Instead, they fall into a rhythm where product placement becomes predictable and efficient.

This is where you start to see real gains in throughput. Not because the filling process itself changed, but because the variability was removed upstream. In many cases, companies expect to improve output by adding more labor. In reality, improving the flow of the process often delivers better results without increasing headcount.

 

The Closing Step Is Where Consistency Shows

If opening defines the pace and filling defines the flow, closing defines the final result. This is the step customers actually see. It affects both functionality and presentation.

Tach-It offers multiple closing methods because not every application is the same. The goal is not to force a solution—it is to match the closure method to the product and environment.

Twist Tie Systems

For applications like produce, bakery, and food packaging, twist tie machines provide a balance of speed and presentation. They create a consistent closure that is secure but still easy for the end user to open. In high-volume environments, this consistency matters. Each bag looks the same, feels the same, and performs the same.

More importantly, the operator is not manually tying each bag. The machine standardizes the process without slowing it down.

Tape Bag Sealers

Tape sealing is one of the most widely used methods for a reason—it works across a broad range of applications. Whether you are packaging consumer goods, industrial parts, or general merchandise, tape sealers provide a fast and reliable closure without requiring complex setup.

What stands out here is not just speed, but repeatability. Every bag is sealed in the same position, with the same amount of material, regardless of who is operating the machine. That level of control reduces waste and improves overall consistency across production.

Impulse Sealers

When the application requires a more permanent or protective seal, impulse sealing becomes the right choice. This method creates a uniform sealed edge that helps contain product and maintain integrity during handling and transport.

It is especially effective in high-volume environments where:

• Seal strength matters
• Product containment is critical
• Consistency must be maintained across long runs

Unlike manual sealing methods, impulse sealers remove variation from the process and deliver a clean, repeatable result every time.

 

Bringing It Together: A Complete Bagging Workflow

Individually, each piece of equipment improves a specific step. Together, they create a system.

A typical optimized workflow might look like this:

• Bags are automatically opened and presented
• Products are inserted in a consistent motion
• Bags are sealed using the appropriate method for the application

There are no unnecessary movements. No rework. No variation between operators.

The process becomes predictable. And when a process is predictable, it becomes scalable.

 

Entry Level Automation in Real Terms

Most companies are not looking to jump into full automation. They need something that improves performance without introducing unnecessary complexity. That is exactly where Tach-It fits.

Our approach to bagging follows the same principle as the rest of our product line:

• Start with the step that slows you down
• Improve it with simple, reliable equipment
• Build from there as your needs grow

This is what Entry Level Automation is meant to do. It bridges the gap between manual work and full automation in a way that makes sense operationally and financially.

Bagging should not be the step that limits your output. The equipment does not need to be complicated. It just needs to work together. And when it does, the results are easy to see. Learn more about all of our bag opening and sealing options. 

Repetitive motion injuries (RMIs) are a silent but significant threat to workers in packaging and distribution environments. Every tape pull, label application, box seal, or product bagging action—when repeated hundreds or thousands of times a day—can lead to serious long-term strain. Over time, these motions compound into conditions such as carpal tunnel syndrome, tendonitis, or chronic joint pain.

As companies seek to balance speed, cost, and efficiency, there’s another equally critical priority that can’t be overlooked: worker safety. And it’s not just about meeting OSHA guidelines or checking a compliance box—it’s about protecting people, retaining talent, and creating a work environment that supports long-term health.

In this post, we explore how automation—especially Entry-Level Automation (ELA), semi-automatic, and automatic packaging equipment—plays a vital role in reducing or eliminating repetitive motion injuries. Whether you’re a high-volume distributor, a mid-size fulfillment center, or a growing e-commerce brand, upgrading your equipment can reduce risk and boost productivity.

 

Understanding Repetitive Motion Injuries

Repetitive motion injuries are caused by performing the same physical task repeatedly, often in awkward or unnatural positions. Common packaging-related RMIs include:

• Carpal tunnel syndrome from repeated wrist movements (e.g., sealing or taping boxes)
• Tendonitis from constant reaching, pulling, or gripping
• Lower back and shoulder strain from improper workstation height or layout
• Trigger finger from frequent use of handheld tools

Unlike acute injuries, RMIs develop slowly—making them harder to detect, track, and correct before they lead to lost productivity, workers’ compensation claims, or long-term disability.

According to the U.S. Bureau of Labor Statistics, musculoskeletal disorders (which include RMIs) account for nearly 30% of all workplace injuries. In warehouse and fulfillment settings, the risk is amplified by high throughput and time-based performance targets.

 

Where Repetitive Motion Shows Up in Packaging Workflows

In most facilities, RMIs arise from everyday packaging tasks like:

• Loading and sealing bags using twist ties, heat sealers, or clips
  Taping cartons by hand using hand-held dispensers
• Manually applying labels to products or boxes
• Reaching repeatedly for tape, labels, or packing materials
• Folding or sealing boxes without support tools

Each of these tasks may seem low-risk on its own, but over the course of a shift—or repeated day after day—they create substantial strain. Injuries might not be reported until they become severe, which makes prevention all the more important.

 

How Automation Reduces Repetitive Motion Injuries

The most effective way to reduce RMIs is to eliminate or modify the motion causing them. Automation does exactly that by transferring repetitive actions from people to machines. Here’s how:

1. Entry-Level Automation (ELA) Reduces Manual Repetition

ELA equipment bridges the gap between manual labor and full automation. Machines like Tach-It’s Twist Tie Machines, L-Clip tape applicators, label dispensers, and bag sealers are compact, easy to implement, and take over repetitive steps—like taping, labeling, or sealing—without requiring a complete overhaul of your workflow.

These tools are ideal for:

• Low-to-mid volume packaging operations
• Facilities without full automation infrastructure
• Businesses looking to reduce injury risk without major capital investment

2. Semi-Automatic Equipment Supports Ergonomic Workflows

Semi-automatic tools require limited human interaction while significantly reducing motion. For instance, a semi-auto label applicator might require the operator to place a box on a platform—but it applies the label in the same spot with perfect consistency, every time.

This consistency eliminates twisting, reaching, and hand stress, while improving labeling speed and accuracy.

3. Automatic Systems Eliminate Manual Labor at Scale

Fully automatic systems take over the complete task—from sensing the product to executing a clean application or seal. These machines are ideal for:

• High-volume distribution centers
• 24/7 operations with minimal downtime
• Companies seeking maximum throughput with minimal physical labor

Automated tapers, labelers, and stretch wrappers can cut down motion-related injuries to near zero for the tasks they replace.

 

Case Example: Labeling Without the Strain

Manual label application seems simple—but applying hundreds or thousands of labels per day leads to repetitive wrist, finger, and shoulder movements.

A company using handheld label guns found that operators were reporting hand fatigue and inconsistent placement. By switching to a Tach-It Mini-Con system—a semi-automatic labeler—they reduced strain while also improving placement accuracy and overall speed.

Within weeks, operators reported less fatigue, and throughput improved with fewer labeling errors. It was a win for both safety and productivity.

 

Why Repetitive Motion Injuries Are a Business Issue

Beyond the clear human cost, RMIs come with direct and indirect business consequences:

• Lost time and reduced productivity
• Increased workers’ compensation claims
• Higher turnover and onboarding costs
• Potential OSHA violations or penalties
• Damaged morale and employee satisfaction

Investing in automation may seem like an operations decision—but it’s also a strategic move for HR, compliance, and long-term workforce health.

 

Choosing the Right Equipment for Safety and Scale

Every facility is different—but there are some common areas where repetitive motion risk is high. When assessing where automation can help, look for tasks that involve:

• High volume with manual repetition
• Consistent product shapes/sizes
• Known strain points for operators

Tach-It offers solutions that address these needs across various automation levels:

• Tape Applicators (like the 6425 L-Clip) for sealing cartons without repetitive wrist motion
• Label Dispensers and Applicators for consistent product or carton labeling
• Twist Tie Machines for speed and consistency in polybag or component packaging
• Entry-Level Automation™ Platforms that integrate with existing tables or lines

These machines are engineered not only for performance but also for ergonomics—placing controls, loading zones, and output areas in positions that reduce reaching, bending, or awkward hand placement.

 

Building a Safer, More Productive Pack Station

Safety and speed don’t have to be at odds. In fact, when a packaging station is designed with worker health in mind, productivity often increases.

Here’s how to rethink your pack station layout:

• Eliminate reach: Place tools and materials within easy arm’s length
• Use adjustable-height workstations to support proper posture (BostonTec workstations pair well with Tach-It gear)
• Automate repetitive tasks with labelers, sealers, and applicators
• Train operators on best practices and ergonomics awareness
• Review incident reports or feedback regularly to spot injury trends early

 

Final Thoughts: Automation Isn’t Just a Tech Upgrade—It’s a People Strategy

For companies of all sizes, repetitive motion injuries are a hidden cost—quietly draining productivity and damaging employee well-being. But they’re also highly preventable.

By implementing the right automation tools—from simple label dispensers to fully integrated tape applicators—you can dramatically reduce repetitive strain while improving throughput, accuracy, and consistency.

At Tach-It, our focus is not just on speed—it’s on smarter packaging operations that put people first. Explore our full line of automation tools and let us help you build a safer, more productive operation from the bench up.

Explore our packaging automation solutions

For more than 60 years, Tach-It has been synonymous with reliability and innovation in the packaging industry. Known originally for pioneering  tagging solutions  and twist tie, we earned our reputation by helping businesses improve packaging processes with practical, durable tools. But as the market needs shift and industries evolve, so do we. Welcome to the Evolution of Tach-It—your partner in Entry Level Automation™.

A Legacy of Excellence, A Future of Innovation
We continue to manufacture and support the trusted tools that made us an industry leader, including our renowned twist tie machines and bag sealing products. But we’re also innovating to meet the needs of a more complex world. That innovation comes to life through Entry Level Automation™: an accessible path to automation that helps companies streamline operations, reduce manual labor costs, and keep pace with rapidly changing market demands.

Why Automation? Why Now?
Today’s packaging challenges are more dynamic than ever. Businesses are grappling with rising labor costs, workforce shortages, and increasing demand for speed and accuracy. At the same time, new industries have emerged—from e-commerce to cannabis to health care—each requiring specialized solutions.
Consumers expect fast delivery and reliable packaging, and operations must evolve to stay competitive. That’s why Entry Level Automation is not just a trend—it’s a necessity.

What Is Entry Level Automation?
Entry Level Automation (ELA) is our answer to businesses looking for smart, scalable solutions without the high cost or complexity of traditional automation. Our equipment is:

1. Easy to Use: Designed for fast onboarding with minimal training required.
2. Cost-Effective: Delivering high-quality automation at a justifiable investment level.
3. Supported: Backed by our national service network and decades of technical expertise.

Evolving Products. Expanding Possibilities.
The Evolution of Tach-It includes a full range of automated labeling systems, L-clip tape and label applicators, bag sealers, and packing station tools. Each product is engineered to enhance throughput and optimize workflow across a wide range of industries.
From top and bottom labeling to side application, from tamper-evident sealing to automatic twist tie, we offer automation solutions that adapt to your specific needs—not the other way around.

Moving Forward Together
The Evolution of Tach-It isn’t just about upgraded equipment—it’s about making automation accessible. We’re here to help you navigate change with practical tools, expert support, and a commitment to helping your business thrive. Whether you’re looking to improve efficiency, reduce costs, or scale for growth, we’re ready to help.

Interested in Entry Level Automation?
Explore our full line of solutions, request a demo, or speak with a Tach-It expert to learn how we can help you move forward.