Custom Tear Strip Tape

Custom Tear Strip Tape and Two-Way Mailers

A popular use is the two-way or returnable mailer. The box has a tear strip to open it, and a second strip of peel-and-seal adhesive so the customer can close it again for a return. This is especially useful for clothing brands with high return rates, as the same box goes back without the customer needing tape.

If you send items that are often returned, ask about adding a second adhesive strip alongside the tear strip. It turns one box into a two-way package and makes the returns process easier for your customers.

We can also print instructions near the tab, such as 'Pull to open' or 'Tear here', so the opening is obvious.

Returns-friendly boxes also cut down on customers reusing random cartons or bags for returns, which tends to bring products back damaged. A box built to go both ways keeps your stock protected on the return journey as well as the outbound one, and the reusable mailing bags work on the same principle.

For subscription brands, a printed message on the strip can change from box to box, giving regular customers a small reason to look forward to opening the next delivery.

Printed or Plain Tape

Plain tear tape, usually in white, clear or brown, is the practical choice. It does its job invisibly and suits any design, while a printed tape sits beside branded packing tape as a second place for the logo. Printed tear tape carries your logo, a brand colour or a short message that appears as the strip is pulled. It is a small detail, but it adds a moment of surprise.

Messages like a thank-you note, a hashtag or a simple pattern work well because the tape is narrow, usually between 3 and 6 mm wide. Keep the design simple: a repeating logo or short phrase reads better than detailed artwork.

Coloured tapes are another option, either matched to your brand or chosen to contrast with the box so the opening tab is easy to find.

Printed tape is ordered in rolls with your design repeating along the length, so the message appears in the same place on every box. If you run several box sizes, one printed tape can usually serve them all.

Choosing the Right Tape Strength

Tear strip tape comes in different strengths to suit different boards. Lighter tapes are made for folding cartons and thin board, while heavier tapes are needed for corrugated boards; the board and card types guide explains the flutes. Using a tape too weak for the board will cause it to snap when pulled, while a tape that is too strong is unnecessary and costs more.

Tell us the board you are using and the flute grade, and we will specify the right tape. If you have existing boxes and want to add a strip to a new design, send us a sample so we can match the tape to the board.

The position of the strip matters too. It should run along a line that opens the box neatly without cutting through product or inner packaging, usually just below the lid edge.

Board moisture and storage can affect how cleanly a strip tears, so keep boxes flat and dry before use. Cartons stored in a damp unit can soften, and the strip may then tear unevenly.

Adding a Tear Strip to Your Packaging

Tear strips are applied when the box is made, as part of the production run, rather than added afterwards. That means they are best planned with a new box order, alongside any e-commerce packaging inserts that go in the same box. If you already buy boxes from us, adding a tear strip to the next run is simple: we add it to the dieline and show it on the proof.

Think about where the tab sits. It should be easy to find and grip, usually at a corner or on the front edge. A small printed arrow or a contrasting colour helps customers find it immediately.

For boxes that need to stay sealed until opening, the strip can sit behind a tamper-evident seal, so the customer knows the box has not been opened in transit.

Tell Us the Board and the Flute, Because the Tape Is Matched to Them

A tear strip only works when the tape is stronger than the board it has to cut, so the first thing to send is the board specification of the box it goes into: folding boxboard with its weight, or corrugated with its flute. A tape that is right for a 350 gsm carton snaps halfway across an E-flute mailer. Then decide where the strip runs, usually just below the lid edge with the tab at a corner, and whether the box also needs a second peel-and-seal strip for returns. Say if the tape should be printed or a contrasting colour.

Send the box style, the board and the quantity, and say plain or printed tape, and a custom quote comes by email within one working day, minimums quoted per job. The free design proof shows the strip position and the tab on the dieline. Production takes 4 to 7 working days after approval and free tracked delivery reaches UK mainland addresses in 2 to 3 working days. If strips do not tear correctly, report it within 10 days for a reprint or refund. Brands that seal the outside too often add printed carton sealing tape to the same order.