Whether bespoke shipping boxes, volume reduction or returnable mailing bags, different packaging solutions place different demands on adhesive application.
E-commerce has transformed the world of packaging: diverse items, changing product sizes, small batch sizes and the demand to use as little material and volume as possible shape modern dispatch processes. The adhesive application is a small detail in the process, but crucial for stability, efficiency and the customer experience. The packaging must be securely sealed, survive transportation, be easy to open and ideally also be prepared for a return. At the same time, adhesive consumption, energy requirements, waste and downtime are expected to decrease. This article classifies the most important adhesive applications in various e-commerce packaging types and shows what matters when choosing the right application technology.
Typical adhesive applications in e-commerce
In e-commerce, four typical types of packaging can be distinguished: packaging on demand or wrap-around packaging, volume reduction, paper mailing bags, and corrugated cardboard mailing bags. They all pursue the same goal: to dispatch products securely, efficiently, and as resource-efficiently as possible. At the same time, paper-based, recyclable solutions are gaining in importance in order to reduce plastic packaging and meet regulatory requirements such as the EU Packaging and Packaging Waste Regulation (PPWR).
With Packaging on Demand, the packaging is created directly around the product or multiple products. The cardboard is cut to size, folded and closed with a precise fit. Such wrap-around solutions are particularly suitable when many different product sizes are processed and the packaging should contain as little empty space as possible. The adhesive is typically applied as a dot or bead. Above all, on-demand processes require flexibility and process reliability from the adhesive application.
Volume reducers – also known as height-adjustable on-demand packaging systems – work with pre-made boxes whose height is adjusted to fit the contents. The volume is reduced by bringing the packaging down to the actual product height and then sealing it. Here, too, dot and bead application are mostly used. The challenge lies in the combination of changing heights, high speed and consistent sealing quality.
Paper mailing bags can be produced inline directly around the product or pre-produced in an upstream process (offline). The long sides are usually glued using bead application, while the short side uses a precise full-surface application for a secure seal. If the mailing bags are produced offline, one or two peel-and-seal closures plus a tear strip can also be applied directly to the packaging – here too, very precise adhesive application is required.
Corrugated postal bags combine the characteristics of a bag with the rigidity of corrugated board. In addition to sealing, gluing the liner to the corrugated board may be relevant here, usually using cold glue applied by spray. The other functions are similar to those of paper mailing bags.
Despite differing packaging concepts, all applications place high demands on adhesive application technology.
For machine builders (OEMs), simple integration and maximum flexibility are paramount. Compactly designed, modularly expandable systems with standardised interfaces and flexible connection options facilitate integration into various machine concepts and save valuable installation space.
Process stability and system availability are crucial above all for packaging manufacturers and e-commerce operators. Unplanned downtime has a direct impact on the ability to deliver. Adhesives must therefore be processed gently and be reliably available at all times. Melting units with high system availability, controlled temperature management and demand-driven adhesive supply support a stable production process. Robatech implements these requirements, for example, with the Vision melter.
Saving money starts with adhesive application
The economic efficiency of a packaging process depends not only on the price of the adhesive, but also on precise adhesive application and plant availability. Overdosage increases consumption, while underdosage compromises the quality of the seal.
Even more important are the indirect costs caused by scrap and downtime. Reliable adhesive application keeps the line available. By using fully electric application heads such as the Volta from Robatech, users can not only reduce maintenance costs compared to pneumatic heads, but also save massive amounts of adhesive thanks to the practical stitching function. Short heat-up times and demand-heated components also help to use resources more efficiently.
Product protection, unboxing and returns
The application of adhesive ensures that the packaging arrives unopened. However, packaging not only has to seal securely, but also be easy to open. Especially in e-commerce, unboxing is part of the customer experience. Easy-open features such as tear strips improve handling. Returns are also part of the business model. Double pressure-sensitive adhesive strips allow the packaging to be used multiple times.
Both pressure-sensitive adhesive tapes and tear tapes can be applied directly to the packaging using a precise surface application method. Exact positioning is crucial here to prevent the packaging from sticking together unintentionally during stacking. Specialised slot-die applicator heads, such as the Vivo 18, enable a clean adhesive application and an even coating from start to finish thanks to their optimised cut-off behaviour.
Sustainability through precise adhesive application
Sustainability in e-commerce is achieved through the interaction of material, adhesive, application technology and system availability. Precise adhesive application reduces consumption, waste and energy requirements. Components with short warm-up times and low maintenance requirements also improve the resource efficiency of the line.
Whether wrap-around packaging, volume reduction, paper mailer or corrugated mailer – every e-commerce packaging solution places its own demands on adhesive application. Anyone who views these applications holistically can simultaneously improve packaging quality, cost-effectiveness and sustainability.
As a provider of adhesive application technology for hot-melt and cold-glue applications, Robatech supports packaging manufacturers, machine builders and e-commerce companies along the entire process chain – from integration to precise application for secure, resource-saving packaging.
packaging journal 4/2026
This article was published in packaging journal 4/2026 (September).
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