Carwash Solutions Manufacturer - Case Study

A carwash solutions manufacturer shipping liquid-filled containers needed to confirm that its carton sealing method could withstand real-world handling and meet Department of Transportation (DOT) hazardous package testing requirements outlined in the Code of Federal Regulations (CFR). While no failures had been reported, the weight and movement of liquid-filled packages increased the risk of seal failure during distribution.

In addition, the manufacturer wanted to evaluate its current carton sealing tape alongside alternative options to identify the best balance of performance and cost.

Goals:

• Evaluate five carton sealing tapes to validate performance under drop and impact conditions
• Compare tape adhesion to corrugated cartons to identify the most reliable option
• Reduce the risk of leaks, carton failure, or seal separation during transportation
• Identify a cost-effective sealing solution without compromising performance

Rocket Industrial conducted DOT/CFR-compliant drop and impact testing in its in-house packaging lab to evaluate carton sealing performance under standardized transportation conditions. This testing simulates the drops, impacts, and handling a package may experience during distribution to verify that cartons remain securely sealed and compliant with federal shipping regulations.

Five carton sealing tapes, including the manufacturer’s existing tape and several alternatives, were tested to determine which option delivered the best balance of sealing performance and cost. Testing focused on tape adhesion to corrugated cartons under repeated impact conditions.

Testing conditions included:

• Water-filled liquid containers to replicate real shipping weights
• Two carton configurations for 1-gallon and 2.5-gallon containers
• Top and bottom sealing applied using an automatic case sealer
• A 3.9-foot drop height in accordance with Packing Group II requirements

Each carton was subjected to a five-drop sequence, bottom face, top face, large side, short side, and corner, representing common impact orientations during transportation. Performance was evaluated based on tape adhesion, carton closure integrity, and any signs of seal failure.

• Identified a higher-performing tape than the manufacturer’s existing tape

• Provided a more cost-effective sealing option without sacrificing performance

• Confirmed DOT/CFR compliance through drop and impact testing

• Maintained secure carton seals across all five drop orientations

Rocket's testing confirmed that one tape outperformed the manufacturer’s existing solution while also offering a more cost-effective option. The selected tape maintained secure carton seals across all five drop orientations and met DOT/CFR requirements.