Tape backup remains a trusted solution for long-term data storage, particularly for email systems like Microsoft Exchange Server. However, when environmental controls fail, even enterprise-grade HPE LTO-7 tapes can become unreadable.
This case study details how our team at PITS Global Data Recovery Services successfully recovered mailbox archives needed for a federal litigation case from LTO-7 tapes degraded due to humidity exposure. These tapes were the only available record of correspondence requested by opposing counsel during the eDiscovery phase of an active legal dispute.
The Background: Legal Hold and Archived Exchange Data
Our client was a multi-location healthcare services provider involved in a pending lawsuit related to patient care coordination and communication records. During early discovery, the opposing legal team issued a legal hold requesting historical emails from several employees, including executives and case managers.
The emails spanned a five-year period and were known to exist on Exchange Server backups stored on HPE LTO-7 cartridges. These tapes were part of the company’s archival system, rotated monthly and stored offsite in a remote utility closet within a secondary facility.
Unfortunately, the storage area lacked ventilation and humidity control. After years in storage, the tapes exhibited signs of environmental degradation and could not be read by the client’s LTO-7 drive.
Initial Client Attempt and Escalation
The in-house IT team attempted to restore the backups using their existing infrastructure, but encountered repeated failures:
- Mount errors from the HPE LTO-7 drive
- Tape spool tensioning failures
- Read retries and CRC errors during data extraction
- Exchange-aware backup catalog failed to load in Veeam
With a court-imposed deadline approaching and no reliable backups available, the client engaged us under emergency service terms.
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Tape Recovery and Exchange Data Restoration Process
- Cleanroom Intake and Tape Assessment
Upon arrival, the tapes were evaluated in our ISO-certified cleanroom lab. All four cartridges showed varying degrees of damage, including:
- Slight warping along the tape edges
- Sticky residue near the BOT (Beginning of Tape) area
- Mold traces on one cartridge, likely due to prolonged humidity exposure
2. Tape Cleaning and Stabilization
Each cartridge was manually cleaned using anti-static materials and safe solvents. We carefully removed mold and surface contaminants without impacting the magnetic layer.
3. Drive Matching and Secure Imaging
The tapes were imaged using an HPE LTO-7 Ultrium external drive, calibrated and tested with similar cartridges prior to loading. Imaging was done sector by sector using error-handled methods to prevent head wear and avoid uncorrectable block loss.
- Metadata Reconstruction and Mailbox Recovery
The extracted data consisted of Exchange EDB files, fragmented across multiple backup sets. Using forensic-grade software, we:
- Rebuilt the Exchange database using EseUtil and SoftRecovery methods
- Identified orphaned mailbox fragments using EDB recovery tools
- Extracted complete mailboxes and exported them as PST files, preserving folder structure and metadata
- Filtered mailboxes by legal hold terms, including sender, subject, and date range
- Litigation Chain of Custody Compliance
We generated hash values for each mailbox export and included a chain-of-custody report to validate the recovery process for legal review. The final files were delivered both on encrypted external media and via secure cloud transfer.
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Real Case Details (Confidentially Presented)
- Over 160 GB of compressed Exchange EDB and log data was recovered
- More than 80 user mailboxes were restored, including several flagged by court subpoenas
- All responsive communications from 2016 to 2021 were successfully indexed and exported
- Recovered emails played a critical role in the deposition phase, supporting the client’s defense against claims of negligence and miscommunication
- The recovery process was completed within 72 hours, meeting the court deadline
The client’s legal counsel informed us that without this recovery, they would have faced sanctions for non-compliance with the eDiscovery order. The firm’s CTO later noted that this recovery was “mission-critical to legal continuity and corporate reputation.”
Key Lessons: Environmental Storage Risks for LTO Tapes
This case reinforces the fact that humidity is one of the leading environmental risks to magnetic tape reliability. Even if a tape is never physically touched or mishandled, poor climate control can lead to:
- Weak magnetic signal from moisture exposure
- Sticky debris affecting tape loading and head contact
- Mold, which accelerates surface degradation
- Tension loss, resulting in reel misalignment or jams
Tips for Safely Archiving Exchange Data on Tape
If your organization stores email or litigation-sensitive data on LTO tape systems, consider these best practices:
- Use climate-controlled storage with humidity between 40–60%
- Store tapes vertically in airtight archival cases
- Maintain a catalog of what each tape contains, including backup software version and encryption keys
- Test restore samples annually to detect silent degradation
- Implement offsite redundancy, especially for legal records or compliance archives
Trust PITS Global with Litigation-Grade Tape Recovery
We specialize in recovering data from damaged or degraded tape backups including:
- HPE LTO-5, LTO-6, LTO-7, and LTO-8 cartridges
- Exchange, SQL, SharePoint, and other Microsoft-based systems
- Backups made with Veeam, Commvault, Veritas, and IBM Spectrum Protect
- Tapes affected by humidity, mold, fire, or improper handling
All recovered data is processed securely, documented with a full audit trail, and delivered with integrity verification for legal use.
Contact Us for Secure and Compliant Tape Recovery
If you’re dealing with unreadable LTO tapes and urgent legal deadlines, don’t wait. Contact our tape data recovery experts to begin a risk-free evaluation.
- Call 888.611.0737
- Learn more at Tape Data Recovery Services
Submit your case via the Request Help Form
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