The Challenge

A steel service center in Linz, Austria processes around 280 slit coils and sheet bundles per day across two shifts. Strapping was done with a mix of manual steel tensioners and old pneumatic sealers connected to overhead air lines.

Each coil required multiple straps and frequent tool changeovers, especially when moving between 19 mm and 32 mm steel strapping. Air hose routing caused trip hazards, and operators reported wrist and shoulder strain from manual tensioning. Unplanned stoppages from damaged air lines and leaking fittings were adding up to 35–40 minutes of downtime per shift.

Manual Process

The previous workflow combined manual tensioning and pneumatic sealing at each packaging station. One operator dedicated most of their day to strapping, with overtime during peak weeks.

Before Automation:

• Daily volume: 280 strapped units/day
• Cycle time per unit: 1.7 minutes/unit (manual tensioning 1.2 min + positioning/sealing 0.5 min)
• Total daily time: 280 × 1.7 = 476 minutes ≈ 8.0 hours/day
• Labor cost: 8.0 hours × €25/hour = €200/day
• Rework/issues: 4–5 straps/day re-tensioned or re-sealed due to inconsistent tension and misaligned seals

In addition, air line leaks and coupler failures caused about 30 minutes/day of lost time across the two shifts. Maintenance spent around 1 hour/week chasing leaks and replacing fittings on the pneumatic tools.

Automated Solution

The center installed the ELECTRA M Series Tensioner and Sealer, a battery-powered steel strapping tool with up to 7500 N tension and a tension speed of 3 m/min. The Makita 18 V lithium-ion battery with 20-minute recharge allowed continuous operation using a simple battery rotation system.

Air lines were removed from the main strapping area, and operators now tension and double-notch seal with a single cordless tool. The compact 5 kg design and controlled, repeatable tension significantly reduced physical strain and variability in strap quality.

After Installing ELECTRA M Series Tensioner and Sealer:

• Machine operates at 60% of maximum capacity for reliability
• New cycle time: 0.95 minutes/unit (faster tensioning and integrated sealing)
• Total daily time: 280 × 0.95 = 266 minutes ≈ 4.4 hours/day
• Labor cost: 4.4 hours × €25/hour ≈ €110/day
• Quality improvement: rework reduced to 1 strap/day, with consistent tension and double-notch sealing

Battery changes were organized around breaks, so the 20-minute fast charge did not add any productive downtime. Removal of air lines also eliminated the previous 30 minutes/day of air-related disruptions.

ROI Calculation

Investment:
Machine price: €4,890
Daily savings: Labor: €200 − €110 = €90/day
Downtime reduction: 0.5 hours/day × €25/hour ≈ €13/day
Maintenance reduction: 1 hour/week × €25/hour ≈ €5/day (allocated)
Total daily savings: €90 + €13 + €5 ≈ €108/day
Monthly savings (22 working days): €108 × 22 = €2,376/month
Payback period: €4,890 ÷ €108/day ≈ 45 days (approximately 2 months)

Conclusion

By replacing manual and pneumatic steel tools with the ELECTRA M Series Tensioner and Sealer, the steel service center cut strapping labor time by about 45% and eliminated dependency on shop air at the packaging line. Consistent 7500 N-capable tensioning and integrated sealing reduced rework while improving ergonomics and safety.

“Switching to the ELECTRA M Series removed 8-hour days of manual and pneumatic strapping and brought us down to around 4.5 hours, saving about €108 every day. With a payback of roughly 45 days and no more air line issues on the floor, this tool quickly became our standard for all 280 coils we strap daily.” — Markus H., Packaging Supervisor, Linz Steel Service Center (Austria)