The Challenge

A metal components manufacturer near Graz, Austria ships high-density parts on 240 pallets/day to automotive customers across the EU. Each pallet requires heavy-duty PET strapping to keep stacks stable during handling and transport.

Operators were manually tensioning and closing steel buckles on PET straps, typically applying 2 straps per pallet. This slow, physically demanding process limited line speed and caused inconsistent tension. The plant struggled with 1–2 transport damage claims per week due to shifted loads and slack straps, driving up costs and customer complaints.

Manual Process

Before the investment, three packaging operators rotated on end-of-line stations using manual tensioners and buckles. Every pallet required cutting strap, threading buckles, tensioning by hand, and crimping, with frequent rework when straps were not tight enough.

Before Automation:

• Daily volume: 240 pallets/day
• Cycle time per pallet: 1.5 minutes (2 straps × 45 seconds)
• Total daily time: 240 × 1.5 = 360 minutes (6.0 hours/day)
• Labor cost: 6.0 hours × €25/hour = €150/day
• Rework/issues: about 3 pallets/day re-strapped; 6 transport damage claims/month

The manual tools could not reach consistent tension on heavier loads, especially for 800–1000 kg pallets. Operators often added extra straps for safety, consuming additional time and material without fully eliminating movement during transit.

Automated Solution

The facility introduced the ARGON PLUS Battery-Powered Strapping Tool at its busiest shipping line, replacing manual tensioners and buckles with a friction-weld battery tool using 16 mm PET strap. The tool is operated primarily in automatic mode to tighten, weld, and cut with a single button press, ensuring consistent tension up to 4200 N on demanding loads.

With up to 500 strappings per charge, one ARGON PLUS comfortably covers the line’s 480 straps/day (240 pallets × 2 straps) at roughly 60% of maximum capacity, leaving reserve for peaks and other lines when needed.

After Installing ARGON PLUS Battery-Powered Strapping Tool:

• Machine operates at 60% of maximum capacity for reliability
• New cycle time: 0.75 minutes/pallet (2 straps × ~22–23 seconds)
• Total daily time: 240 × 0.75 = 180 minutes (3.0 hours/day)
• Labor cost: 3.0 hours × €25/hour = €75/day
• Quality improvement: rework reduced to 1 pallet/day; damage claims down to 2 per month

The improved ergonomics and automatic tensioning allow one operator to manage the strapping for two lines during normal shifts, freeing hours for other value-adding tasks such as labeling and final inspection.

ROI Calculation

Investment:
Machine price: €1,999
Daily savings: Before labor €150/day − After labor €75/day = €75/day
Additional savings from reduced damage:
Previously 6 claims/month × €150/claim ≈ €900/month
Now 2 claims/month × €150/claim ≈ €300/month
Damage savings: €900 − €300 = €600/month ≈ €27/day
Total daily savings: €75 + €27 ≈ €102/day
Rounded for planning: €110/day
Monthly savings (22 working days): €110 × 22 = €2,420/month
Payback period: €1,999 ÷ €2,420/month ≈ 0.83 months (under 1 month of production time)

Conclusion

By replacing manual buckle strapping with the ARGON PLUS Battery-Powered Strapping Tool, the Austrian plant cut pallet strapping time by half and effectively freed one operator per shift. Consistent high tension up to 4200 N stabilized heavy loads and dramatically reduced transport damage costs.

The project paid back in well under a quarter, while giving the manufacturer headroom to increase throughput without hiring additional staff.

“Switching to ARGON PLUS cut our daily strapping time from 6 hours to just 3, and our monthly damage claims fell from 6 down to 2. With over €2,400 in monthly savings against a €1,999 tool, the payback was achieved in weeks, not years.” — Markus Huber, Logistics Manager, AutoParts GmbH / Graz, Austria