Choosing the Right Strapping Materials for Your Product

When it comes to securing your products for shipment, selecting the right strapping materials is critical. This decision impacts not only the safety and integrity of your goods, but also your operational efficiency and overall costs of delivery. Improperly applied strapping can increase pressure on products, crushing and damaging them unnecessarily.

Corrugated products like cardboard and paperboard need to be properly compressed, which means the strap used should maintain its tension and allow minimal amounts of give in the bundle. This article explores the key considerations for corrugators in choosing the right strapping materials, from manual versus machine strapping tools to the differences between steel and polyester strapping.

MANUAL VS. BATTERY-POWERED: CONSISTENCY AND EFFICIENCY

A big decision when choosing a strapping solution is whether to go with manual or battery-powered tools. Manual tools require the operator to manually ratchet the tension of the strapping material. A manual process not only demands physical effort, it also leads to inconsistencies in tension application across different operators or when there is employee turnover.

Additionally, manually applied strapping often results in lower joint efficiency—a measure of the percent of the strap break strength at the joint. With manual tools, it is typical to achieve around 60 percent joint efficiency because a mechanical closure is required, such as a wire buckle or seal, to fasten the straps together.

A friction welded PET strap.

Battery-powered strapping tools offer a more efficient solution. These tools consistently apply high tension, creating a friction weld that bonds the two pieces of strapping material through heat. This process increases joint efficiency to around 85 percent. The higher joint efficiency means that the strapping can handle more force without failing, reducing the likelihood of product damage during transit.

In addition to better performance, battery-powered strapping tools also reduce the risk of workplace injuries. Workers are no longer required to manually ratchet tension, which can be a strenuous task, especially when done repeatedly. This noticeable reduction in physical strain contributes to fewer reported repetitive motion injuries, improving overall workplace safety.

When deciding whether to invest in battery-powered strapping tools, it’s important to consider several factors. The first is how often your team will be strapping products. If you’re palletizing only a few times a day, manual tools may be sufficient. However, if your plant is strapping double-digit pallets per shift, the consistent performance and reduced labor of battery-powered tools will quickly pay off.

Another key consideration is who will be operating the tools. If multiple people will be using the strapping equipment, machine tools offer more consistent results, regardless of the operator’s experience or physical strength. Additionally, the cost savings from fewer injuries and higher joint efficiency can have a noticeable impact on your bottom line over time.

STEEL VS. POLYESTER STRAPPING

There has been a growing shift away from steel strapping toward polyester strapping, and for good reason. Steel has long been a trusted material, especially for heavy-duty applications, but it comes with significant drawbacks. Steel is heavy, difficult to handle, and poses safety risks due to its sharp edges and the potential for “spring back” when cut. These factors not only increase the risk of injuries, but also drive up operational costs through higher insurance premiums and medical expenses. Steel is also less environmentally friendly, as it’s not as easily recycled and reused.

Polyester, on the other hand, is a lighter, more flexible alternative. For corrugators, a high-performance polyester strap designed to retain tension and recover from elongation is ideal for plants that produce mass volumes of corrugated products.

From an environmental perspective, polyester is more sustainable than steel. It’s made largely from recycled material, is easier to recycle, and uses less energy in the production process, making it a more eco-friendly choice for plants looking to reduce their environmental impact.

A coil of polyester strapping weighs about half as much as steel, making it much easier for operators to handle. In addition, polyester’s “rubber band” effect allows it to stretch and contract with the load, which helps maintain tension during transit. This elasticity is particularly important for shipments where the load may shift slightly, as the strapping will remain tight and continue to secure the product effectively without applying too much, or too little, support.

JOINT EFFICIENCY AND STRAPPING SELECTION

One of the most critical factors in selecting a strapping method is joint efficiency. As mentioned earlier, manual tools typically offer around 60 percent joint efficiency, while battery-powered tools with friction weld technology can achieve up to 85 percent. The higher the joint efficiency, the more secure your load will be during transit. This becomes particularly important when shipping heavy or valuable goods, where even a slight shift in the load could result in significant damage.

When businesses switch from manual to machine strapping, they often see a decrease in product damage claims. A more secure load means fewer instances of broken or shifted products, which in turn reduces the need for costly replacements or returns. Over time, this leads to long-term cost savings while improving customer satisfaction by ensuring products arrive in pristine condition.

Switching to battery-powered tools offers another potential benefit: the ability to down-gauge the strapping material. With manual tools, the lower joint efficiency often requires a heavier gauge strap to provide adequate load security. However, battery-powered tools’ friction weld technology yields a stronger bond, allowing operators to confidently use a lighter gauge strap without compromising stability. This adjustment can translate into significant material savings over time, particularly for high-volume applications, by reducing both material usage and the overall weight of each shipment.

CUSTOM FOR CORRUGATORS

PAC Strapping Products, Exton, PA, offers sturdy, reliable, and cost-effective materials and equipment for use with all kinds of corrugated products, from basic carton to triple-wall boxes. The materials PAC provides allow for tight strapping, bundling, and palletizing of compressible cardboard products that prevent unwanted expansion. PAC Strapping has been at the forefront of developing customized strapping solutions, and offers a range of products and technologies geared toward a variety of industries, including corrugated packaging.

Bundled and palletized corrugated products get heavy, so manufacturers need strapping that can handle the weight requirements. PAC’s high performance polyester strap is ideal for bundling, packaging, and palletizing operations since its high break strength and tension retention keep strapped products stable and secure. This machine-grade polyester strap is specially designed for the rigors of the paper and packaging industry with the following offerings:

• Machine and friction welding options
• Low elongation compared to polypropylene strap
• High ability to retain tension
• Good elongation recovery
• Excellent recyclability
• Strong shock resistance

Polyester strap can be applied by hand, with manual and powered tools, and with automatic machines. For smaller bundles, low elongation polypropylene strap may be used as a substitute in certain cases. The type, grade, and width of strap used should be based on the scale and nature of the paper or corrugated operations.

PAC’s strapping machines and palletizing systems are designed to be swift and reliable, and they boast many features that prevent bottlenecking and lost production. Equipment designed for corrugated strapping applications include:

• Semi-automatic strapping machines for off-line applications.
• Fully automatic machines with integrated conveying systems.
• End-of-line bundling strappers that will strap flat cartons in any direction and with multiple patterns.
• Strapping systems designed to handle either palletized cartons or slip sheets.
• Manual and powered hand tools for strapping larger sized product in operations with lower production rate requirements.

Corrugated manufacturers may also want to consider accessories such as seals, buckles, dispensers, and edge protectors.

NAVIGATING THE FUTURE

Choosing the right strapping materials and tools for your corrugated plant is a decision that impacts everything from workplace safety to operational efficiency and product integrity. While manual tools may work for smaller volume operations, battery-powered tools offer significant advantages in terms of consistency, joint efficiency, and safety. The shift from steel to polyester strapping represents a move toward more sustainable, cost-effective, and safe solutions.

By working with a company like PAC Strapping that will tailor solutions to meet specific corrugated packaging industry needs, plants can ensure that their products are securely strapped and ready for safe transit, no matter what challenges lie ahead.