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An e-commerce fulfillment center in northern Italy was shipping over 18,000 cartons per shift on mixed-size parcels. Their stand-alone HIPO ULTRA Auto Strapping Machine required operators to pull cartons off the conveyor, strap them, and push them back to the outfeed line. This created extra touchpoints, queuing, and occasional mis-strap issues when operators rushed.
Management wanted to raise throughput by at least 50% on the shipping line, cut manual handling, and stabilize quality without adding headcount. The comparison came down to keeping the existing HIPO ULTRA Auto Strapping Machine (Product B) or upgrading to the inline HIPO ULTRA-B Automatic Strapping Machine with Conveyor Belt (Product A).
The HIPO ULTRA Auto Strapping Machine delivers up to 72 cycles/min with a standard arch of 650 × 500 mm and worktable height of 850 mm. In the fulfillment center, real performance was limited by manual loading/unloading, averaging around 20,000 cartons/shift at roughly 60% of theoretical capacity.
Two operators per shift were needed to handle carton transfer between conveyors and the machine, at a labor cost of about €25/hour each. At an 8-hour shift, this translated to €400/day in direct labor just for the strapping station, plus time lost to mis-placed boxes and occasional mis-straps that required rework.
The HIPO ULTRA-B integrates a high-speed strapping head with an automatic conveyor, enabling true inline operation at up to 50 cycles/min. Even at 60% utilization, the fulfillment center achieved a stable 30,000 cartons/shift without manual carton transfer.
PP straps of 5–9 mm, adjustable tension up to 30 kg, and a standard 650 × 500 mm arch ensured compatibility with the existing carton mix. The 1.0 kW power consumption and ≤75 dB(A) noise kept energy and HSE impact low. Most importantly, inline sensors and conveyor synchronization removed a full operator from the station while reducing mis-straps and jams.
Product B Performance:
Product A Performance:
Investment Comparison:Product B price (existing HIPO ULTRA): €3,799Product A price (HIPO ULTRA-B): €6,999Price difference: €3,200Daily savings with Product A (labor only): €200/day less labor + reduced rework not yet countedPayback on price difference: under 1 month on labor savings alone; even assuming partial utilization and downtime, the center calculated payback at under 2 months.
Beyond direct cost, the extra 10,000 cartons/day capacity allowed the site to absorb seasonal peaks without overtime or temporary staffing, further improving ROI.
Choose Product B if your budget is strictly under €4,000 and your carton volume stays below 10,000 units/day on a single shift, with operators already dedicated to manual handling.
Choose Product A if you run continuous e-commerce or logistics operations, need more than 15,000–20,000 cartons/day, and want to remove manual touchpoints between conveyors. The HIPO ULTRA-B’s integrated conveyor, consistent 50-cycle/min performance, and one-operator layout make it the superior long-term investment for most fulfillment centers.
“Switching from our stand-alone strapping station to the HIPO ULTRA-B inline system cut one full operator per shift and increased our outbound capacity by more than 40% during peak season. Mis-straps almost disappeared, and our shipping line finally keeps pace with picking.” — Luca Bianchi, Operations Manager, FastPack Logistics / Bologna, Italy
