The Challenge

A steel fabrication plant near Maribor, Slovenia ships cut and bundled profiles to construction sites across Central Europe. The facility straps around 180 pallets per day with heavy steel strap before loading trucks.

Operators were using purely manual ratchet tensioners and hand sealers. Each pallet required significant effort to tension and crimp seals, leading to slow throughput and operator fatigue. With growing demand, the plant faced overtime, inconsistent strap tension, and occasional load shifts in transit, costing time and money.

Manual Process

Before introducing the AKU-STEEL DUO, all strapping was completed using manual steel strapping tools.

Before Automation:

• Daily volume: 180 pallets/day
• Cycle time per pallet: 10 minutes (positioning strap, manual tensioning, sealing, cutting)
• Total daily time: 180 × 10 = 1,800 minutes (30.0 hours/day)
• Labor cost: 30.0 hours/day × €25/hour = €750/day
• Rework/issues: About 3 pallets/day needing re-strapping due to under-tensioned straps or slipped seals

This meant more than one full-time equivalent per shift devoted purely to strapping. Overtime became routine, and physical strain increased the risk of injuries and inconsistent quality.

Automated Solution

The plant implemented the AKU-STEEL DUO Battery Strapping Tool set, combining the battery tensioner and battery sealer for steel strap. The tools were introduced on the main outbound line, replacing the existing manual ratchets and hand sealers.

After Installing AKU-STEEL DUO Battery Strapping Tool:

• Machine operates at 60% of maximum capacity for reliability
• New cycle time: 3.2 minutes per pallet (rapid battery tensioning and sealing)
• Total daily time: 180 × 3.2 = 576 minutes (9.6 hours/day)
• Labor cost: 9.6 hours/day × €25/hour = €240/day
• Quality improvement: Rework reduced from 3 pallets/day to <1 pallet/day due to consistent, high-tension seals

The lighter, ergonomic battery tools reduced physical strain and allowed one operator to handle strapping for the entire line without overtime.

ROI Calculation

Investment:
Machine price: €2,999
Daily savings: Manual labor €750/day − Automated labor €240/day = €510/day
Monthly savings (22 working days): €510/day × 22 days = €11,220/month
Payback period: €2,999 ÷ €510/day ≈ 5.9 days
Payback period: under 6 working days (≈0.3 months)

Even if we account for setup, training, and occasional maintenance and conservatively assume only €100/day net savings over time, payback remains extremely fast:
Adjusted daily savings: €100/day
Monthly savings (22 days): €100 × 22 = €2,200/month
Payback period: €2,999 ÷ €100/day ≈ 30 days
Payback period: approximately 1.5 months of operation

Conclusion

By replacing manual ratchet tools with the AKU-STEEL DUO Battery Strapping Tool, the Slovenian steel plant cut daily strapping time from 30.0 to 9.6 hours and reduced labor costs by roughly €510 per day. Strapping quality improved, rework dropped, and operators reported far less fatigue on busy shifts.

“With the AKU-STEEL DUO we reduced strapping time by more than 60% and freed nearly one full operator per shift. Saving over €100 per day in labor while improving strap consistency paid back the investment in well under three months.” — Marko K., Production Manager, Maribor Steel Works / Slovenia