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Hot Melt vs. Acrylic Tape:  Which Costs Less?

Deciding between hot melt and acrylic tape? They each have their uses, but one factor to keep in mind is always cost. You may be wondering which type of tape is most cost-effective: hot melt or acrylic? Read on to find out.  

 

Cost Differences Between Hot Melt and Acrylic Tape


Acrylic tape was originally designed as an economy tape, but that is no longer necessarily the case. Currently, we are seeing prices for acrylic tape 10-15% higher than hot melt. For example, when comparing costs for 1.6 mil, 2” acrylic tape vs. hot melt tape with the same parameters, that translates to about $0.20 more per roll for the acrylic.  

 

Traditionally, hot melt tape was more expensive than acrylic tape. Hot melt tape is considered a higher quality tape due to its higher “stickiness.” With a quick tack and easier release, it works exceptionally well for sealing corrugated cartons. Acrylic tape was created as a lower-cost alternative to hot melt tapes. However, rising costs for the chemicals used in acrylic tape have driven up costs. As a result, acrylic tape is currently more expensive than hot melt tape. This could change in the future, as prices for packaging tape are highly dependent on raw material costs and other supply chain variables.  

 

Why has the cost of acrylic tape gone up? 


The cost of acrylic tape is tied to the cost of the chemicals and petroleum used to create it. Acrylic adhesives are made using petroleum, so the cost of acrylic tape is tied to the petroleum market. When petroleum costs go up, the manufacturing cost for acrylic tape goes up, too. During the COVID-19 pandemic, sharp rises in petroleum prices drove up manufacturing costs for acrylic tape. In addition, pandemic-related surges in online shopping created additional demand pressure for acrylic tape in the ecommerce sector. As a result, prices for acrylic tape have gone up substantially during the pandemic. Acrylic tape is now more expensive than hot melt tape, though this may change in the future.  

 

Which is the better value, hot melt or acrylic packaging tape? 


While acrylic tapes were historically considered to be economy tapes, supply chain issues have driven up costs during the pandemic. That makes hot melt tape a better value for most customers right now. Hot melt tape is a higher quality tape for most applications. Since it is now also cheaper, that is a double win for tape purchasers. Hot melt tape offers a number of benefits for many applications:  

  • Higher initial tack and better “stickiness” 
  • Easier to tear by hand 
  • Higher holding power 
  • Quieter application  

     

    There are exceptions, however. The best tape value is the one that meets your needs for the lowest possible price. Acrylic tapes perform better in cold temperatures and have longer staying power. Stick with acrylic tape for: 

    • Cold environments 
    • Extended storage  

     

    Many companies have relied on value-priced acrylic tapes to keep costs down. Now that prices have flipped for acrylic and hot melt tape, it may be a good time to rethink your tape choice. If you don’t have a good reason to stick with acrylic (such as temperature considerations), switching to hot melt tape could give you a better-quality tape for a better price.  

     

    Packaging Tape Cost Considerations 


    Many factors influence the cost of packaging tape, including materials, quality and size. When comparing prices between different types of tape, it is important to make sure all of the specifications between the rolls are the same, so you know you are comparing apples to apples. This includes: 

    • Width (for packaging tape, usually 2”-3”) 
    • Length (usually in yards per roll in the U.S.) 
    • Thickness or grade (typically measured in mils; 1 mil = 1/1000 of an inch)  

     

    One thing you don’t need to worry about? Clarity. While a crystal-clear tape may be preferable for presentation purposes, a clearer tape does not indicate a higher-quality tape. In fact, sometimes very clear tape is harder to get off the roll. Don’t look at clarity or color when determining the strength or quality of a tape.  

     

    What drives costs up for packaging tape? 


    Outside of the supply chain and material costs explained above, the biggest driver for packaging tape costs is the thickness or grade. Both acrylic and hot melt tape come in mil thicknesses of 1.6 mil to 3 mil. This measurement includes both the backing and the adhesive. The thicker the tape, the more adhesive and strength it will have. A thicker mil tape is also more expensive.  

     

    The weight of the boxes you are sealing will determine the mil thickness needed. If you are packaging very heavy boxes, you will need to have a thicker tape, which will drive up your supply costs.  

     

    Another factor that may influence packaging tape costs is the type of box that you are using.  

    Boxes with high levels of recycled content make it harder for tape to adhere effectively. If you are using boxes made with lots of recycled material, you may need to consider a more expensive adhesive to compensate. A 2.5 mil hot melt tape with a natural rubber adhesive works well for these boxes.  

     

    There are also hidden costs to look out for when purchasing acrylic or hot melt tape—such as freight costs and service charges tacked on by some suppliers. Tape is a relatively heavy commodity, so if you are paying freight charges by weight that can add a lot to the total purchase price. And some suppliers add a convenience charge for same-day/next-day shipping. These costs can add up quickly, driving up your total material costs.  

     

    How can you reduce your packaging tape costs? 


    To keep packaging tape costs under control, look at several factors.  

    • Tape type: Make sure you are using the cheapest type of tape that works for your application. In most cases right now, that will be hot melt tape.  
    • Width: Narrower rolls are cheaper, but you may end up using a lot more. A single strip of 3” tape will be less expensive than multiple strips of 2” tape to seal the same box. Using the correct box, and training employees in correct taping procedures, will allow you to get away with narrower tapes and reduce your material costs.  
    • Thickness: There is no sense in paying for a higher-thickness tape than you really need. Save thicker tape for the heaviest boxes and use a thinner tape for general-purpose sealing.  

     

    Also, make sure you are working with a trustworthy supplier and you understand all of the shipping and service charges. Freight costs can add quite a bit to your total bill, so look for a supplier that offers free delivery options. A local supplier can often get materials to you faster—even same day or next day—without excessive delivery charges.  

     

    But watch out for deals that look too good to be true. Some companies import tape that is of lower quality or does not have the specifications advertised. A low-quality tape with inferior backing or adhesive materials is likely to fail, leading to expensive inventory losses or damage. And some manufacturers simply try to cheat the system, deliberately mis-stating the mil thickness or yardage for the tape. Make sure you are working with a trustworthy supplier who stands behind their inventory.  

     

    The Best Packaging Tape Value 


    The best packaging tape value is the tape that meets your needs with the highest possible reliability and performance and the lowest cost. Whether that means acrylic or hot melt, Benchmark has you covered. We can help you determine which type of tape is best for your application and find the best value for your needs.  

     

    Benchmark provides the best value for hot melt and acrylic tapes.  

    • Inventory: Wide inventory of tapes for general-purpose packaging and specialty applications.  
    • Expertise: Product experts who can help you find the lowest-cost option that will meet your needs.  
    • Free delivery: We offer free next-day local delivery for all orders of $150.  
    • Price-match guarantee: if you find acrylic or hot melt tape at a lower price anywhere, we will match it.  

       

      Need help deciding between acrylic and hot melt tape? Talk to one of our product experts.