1. Scenario Overview

The company packs 200 boxes/hour using manual or semi-automatic stations. We compare the operation before vs after installing the LINEBOX-03 Packaging Line (720 boxes/h).

• Required throughput: 200 boxes/h
• Machine capacity: 720 boxes/h → runs at very low load → high reliability
• Shift: 8 hours/day, 22 days/month
• Machine price: €15,499

2. Key Metrics (Before vs After)

3. ROI Calculation (200 Boxes/Hour)

Labor savings

Before: €40/h
After: €20/h
Savings: €20/h

Monthly savings

€20 × 8h × 22 days =
€3,520/month

Payback period

€15,499 ÷ €3,520 ≈
4.4 months

Annual savings

€3,520 × 12 =
€42,240/year

4. Operational Benefits

Reliability & Capacity

• Machine runs at less than 30% of its maximum speed, ensuring extremely low wear and long lifespan.
• Consistent output without fatigue or variability.

Quality

• Perfect forming and sealing of cartons
• Reduced tape usage due to controlled tape length
• Lower rework and returns

Space & Workload Reduction

• Replaces two manual workstations with one automated line
• Only one operator needed (loading and supervision)

Scalability

• If production needs increase from 200 to 300, 400, or even 720/h, no extra labor is required.

5. Financial Outcome After One Year

Total annual savings

• Labor: €42,240/year
• Tape waste reduction: ~€600–€1,200/year
• Reduced damage/rework: €300–€1,000/year

Total estimated benefit:
€43,000 – €44,400/year

Net benefit after 12 months

Machine cost: €15,499
Annual benefit: approx. €43,000
Net return after year 1: ~€27,000 profit

6. Conclusion

At 200 boxes/hour, the LINEBOX-03 packaging line provides:

• 50% labor cost reduction
• €3,520/month savings
• 4.4-month payback
• Strong long-term profitability
• Significantly improved consistency, quality, and operational control
• Enough headroom for future growth without extra staff

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The Prestretch pallet wrapping machine is a revolutionary piece of equipment that can help you reduce your film costs by up to 36%. Let’s take a closer look at how it works and the benefits it can provide for your business.

How Does the Prestretch Pallet Wrapping Machine Work?

The PRESTRETCH pallet wrapping machine works by stretching the film before it is applied to the pallet. This stretching process, also known as pre-stretching, allows you to use less film while still achieving the same level of load stability.

When the film is stretched, it becomes thinner and more elastic, which means that it can be applied more tightly to the pallet. The result is a more secure load that is less likely to shift or become damaged during transport.

Benefits of Using the Prestretch Pallet Wrapping Machine

There are many benefits to using the PRESTRETCH pallet wrapping machine, but perhaps the most significant is the cost savings. By using less film, you can significantly reduce your film costs. In fact, you can expect to save up to 36% on your film costs when you use the PRESTRETCH pallet wrapping machine.

But the benefits don’t stop there. Here are a few more reasons why you should consider investing in a stretch pallet wrapping machine for your business:

1. Improved load stability

The pre-stretching process used by the Prestretch pallet wrapping machine results in a more secure load. This means that your pallets are less likely to shift or become damaged during transport. The end result is a more reliable supply chain and fewer returns or lost inventory.

2. Reduced Environmental Impact

By using less film, you can reduce your environmental impact. This is because film is a petroleum-based product that takes a long time to break down in the environment. By using less film, you can reduce your carbon footprint and help protect the planet.

3. Increased Efficiency

The Prestretch pallet wrapping machine is a highly efficient piece of equipment that can help you streamline your pallet wrapping process. With faster wrapping speeds and less downtime for film changes, you can increase your productivity and reduce labor costs.

4. Improved Aesthetics

The pre-stretching process used by the Prestretch pallet wrapping machine results in a more uniform and aesthetically pleasing wrap. This can be important for businesses that want to present a professional image to their customers.

Conclusion

If you’re looking for a way to reduce your film costs and improve the stability of your pallet loads, the PRESTRETCH pallet wrapping machine is definitely worth considering. With significant cost savings, improved load stability, and a range of other benefits, this innovative piece of equipment can help take your pallet wrapping process to the next level. So why not invest in a stretch pallet wrapping machine today and start reaping the benefits for your business?

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Packaging or otherwise called strap linking is a process in which the strap is used in order to secure the item to a substrate, stabilize it or strengthen it. A strap can be also called a packing belt. Packaging is mainly popular in the manufacturing industry.

Steel strapping/packing

Steel straps are those that are considered under the oldest packaging and bonding materials and at the same time have the highest tensile strength. They are available in different widths and thicknesses, and they differ in quality from one another. They are mainly used for heavy economy, where a high level of endurance is required. The surface of the tape includes paint, paint or wax and zinc and wax. The tape wax is used to better tolerate the tension and to use the tape in pairs with certain types of tensioners. Steel strips are sold by weight and not by length because they shrink and expand during the production process.

Polypropylene PP strapping/packing

Polypropylene is an economical material designed for medium-length bonding. It is available in different widths, thicknesses, and versions of polypropylenes. An important feature of this tape, which many users do not know, is that the polypropylene straps lose 50% of the elongation voltage after one hour and that the loss of voltage is only accelerated by increasing the temperature. A careful choice of color will inhibit the degradation process of the tape at an outside temperature that is not suitable for it.

Polyester PET strapping/packing

Plastic polyester and nylon are the most powerful plastic materials for the production of strips and are used in many industries as the first best alternative to the steel strap. Polyester provides excellent tension for rigid loads. The types of tape vary mainly by what kind of purpose it is used. In the cold climate, a strip bound in a hot glue that is weather resistant is used.

Nylon

The nylon tape has the highest power among all plastic strips, but due to its high price, it is rarely used. In the past, this was very popular, but soon it was replaced by a polyester tape. It is most commonly used in cold rooms, as it does not lie just like other types of plastic.

Composite strapping/packing

Composite tapes incorporate filaments inside. In the industry that protects the load, it is often called “synthetic steel”. It is very resistant to wear.

Fabric

Woven strips are available in several structures, especially with polyester and rayon. Since the packing system with this type of tape is using a fastener, such a system can offer even greater strength than a steel strip packing. Because the fabric straps are light and soft, they are a safer alternative to steel.

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PP strap is a thermoplastic addition polymer, made from a combination of polypropylene monomers. It is used for various applications, but it is especially useful for packing consumer goods, plastic parts for various industries, including the automotive industry, etc. … Polypropylene was discovered in 1951 and its main inventors were Paul Hogan and Robert Banks. Polypropylene as a material has become popular extremely fast. Commercialized production began three years after the invention. By 1957, its popularity was growing, but today it is one of the most widely produced straps in the world.

The most efficient way of packing with PP polypropylene strap?

PP polypropylene packing can be manual or automatic. PP strap is used for packing boxes, packages, and pallets. The most efficient and fastest way to pack boxes is using automatic or semi-automatic machines, like for example HIPO semi-automatic packing machine. Boxes and pallets can be also packed with battery strapping tool. Moreover, with battery strapping tool you can also pack pallets, however, the fastest way to pack pallets might be with semi-automatic pallet packing machine, which allows you to send strap under the pallet and connect (weld) it with a help of a strapping machine. This can be done for example by our COMBO pallet strapping machine.

What are the properties of polypropylene?

The first important feature is its chemical resistance. Diluted bases and acids do not react easily with polypropylene, which makes it a good choice when packing liquids such as various cleaners, first aid products, and others. The other main feature is elasticity and at the same time toughness. The latter is an engineering term that is defined as the ability of the material to deform without breaking. The third characteristic is considered the preservation of the shape. Polypropylene maintains its shape after torsion or bending and is therefore much more durable than other masses. The fourth property is insulation. Being highly resistant to electricity, it is very useful in all electronic components. The fifth property is portability. Although polypropylene may be transparent, it is usually not produced in this form. This address can be used for applications where light transmission is important.

Why is polypropylene used so often?

Polypropylene is mostly used in industry. Its unique properties and the ability to adapt to different manufacturing techniques make it an invaluable material for a wide range of applications. Its other feature is that it can be used as a plastic material or as a fiber. In modern times, it has replaced many old materials, especially in the packaging industry.

What types of polypropylene are known?

Two main types of polypropylene are available: homopolymers and copolymers. The copolymers are further subdivided into block copolymers and random copolymers. Each category is better for some applications than others. Polypropylene is often referred to as the “steel” of the plastics industry due to various ways in which it can be modified or adapted to serve the purpose for a particular purpose. This is usually achieved by introducing specific additives or by processing in a very special way. This flexibility is also one of the essential features.

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For each distributor, customer satisfaction must always be the first priority. This is considered to be the fact that what the customer orders, he also gets. If the latter does not materialize, this is often due to poor packaging practices or improper storage. Thus, tracking and maintaining packing standards is an important element in achieving customer satisfaction. Taking into account good practices, you will reduce costs, prevent various injuries and other disadvantages.

How to increase production when packing/strapping?

When companies in anyway automize packing/strapping activity, they speed up packing and reduce the time which is needed for packing. Usually, semi/automatic packing can be faster by at least 300%. Additionally, automatic packing it usually safer and employee friendlier. If you are packing boxes, the best way to speed up the packing is by using HIPO semi-automatic packing machine, which automatically straps the boxes with PP strap. For pallet strapping, we suggest COMBO semi-automatic strapping machine or battery strapping tools, which can be also used for boxes/packages.

The packaging of basic products

If the basic products are not packaged in boxes, they must not be packaged in the usual way. In the event that the product has a container with an opening showing the contents of the package, this opening must be adequately protected by a protective plastic. This is necessary because the carton packaging breaks down while transporting, and dust particles are generated which can hurt the products. Exposure protection is essential to ensure that the product as a whole comes to the customer to ensure its satisfaction. Products such as clothing should be packaged in plastic bags, where each unit is packaged in its own bag.

Internal packaging

When talking about internal packaging (storing the product inside the main body), it is wise to use solid cardboard that allows better handling of packaged products in the warehouse. The suitability of packaging also depends on the product specification, so before packing it is worthwhile to consider how weight, size and other product features can affect the quality of the packaging.

Packaging materials and additional protection

Each distributor is responsible for sending the goods to reach their destination intact. For this reason, it is important for him to pay special attention to the packaging and storage of products. In the case of glass products, the distributor must ensure that these boxes are separated by means of manifolds in between the boxes and thus are not damaged or distorted during transport. If the items are fragile, they need to be individually packed in boxes, etc… For additional protection, you can also make sure that you fill the empty space in boxes with paper, cardboard or other fillers, which must be of non-aggressive materials.

Proper packing that follows the standards makes it possible for you to be more credible in the eyes of your customers, and at the same time, the cost product damage is much lower.

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This type of product offers the possibility of greater elongation, but stretching at some point stops, especially when the tape is subject to a constant load.

Packing with polypropylene PP strap is most efficient when using battery strapping tool. Because of that, you will save time and material. When packing with battery banding machine you don’t need clips for packing.

It is not known to the end users that the PP strip will lose 50% of the applied voltage already in an hour, while the loss of voltage will only increase with the increase in room temperature. Therefore, PP strap needs sufficient tensile strength. To speed the packing and operate with sufficient tension most industries are using automatic solutions. The PP tape can be printed, which provides additional marketing benefits.

Advantages: Cost-effective, efficient, easy, easy to use and recyclable, high elongation, reuse.

Weaknesses: low elongation load, not suitable for heavy objects sensitive to environmental factors, greater wearability if used in sharp, hard objects

Methods of application: hand tools, manual tensioner, and stapler, battery tensioner and stapler, semi-automatic machine, automatic machine

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Industrial packaging is just as important as the product itself within the package. Its purpose is to facilitate the transfer of products to stores. It also enables faster product recognition. The most important feature of the industrial packaging is the protection of the product. Therefore, it must be coordinated with the purpose and storage environment. It is important that industrial packaging meets all or any of the following criteria:

• It must be strong enough and durable to withstand permanent load (heavy cardboard boxes stacked together)
• It must ensure the product and, in the event of a fall, to alleviate it
• It must be sufficiently sealed to prevent moisture and air from entering
• It must be weather resistant, which could destroy the quality of the product
• It must be compactly packaged, as it ensures to the customer that no product has been opened before it
• Our packed material satisfies all of the above conditions, thus providing customers with lasting satisfaction, which is reflected through their loyalty. It is important for a customer to know that, in the case of non-quality packaging material, there may be more costs at the end than in the case of a little more deducting at the beginning for good quality.

The above conditions must be met in full, in particular, when the packaged product is exposed to different weather conditions and longer transport. Therefore, it is necessary to choose the right strategy, which aims at lower costs and the safety of packaged products. Here are ten ways to save on industrial packaging: 1. Assess the requirements of each product

1. Evaluate the requirements of each product

Thoroughly evaluate the prescribed packing requirements that are attributed to each product and then compare them with your current practice (for example, you may find that both plastic film and thinner board are suitable for packaging a particular product) .2. Check that the packing boxes are of the right size

2. Check that the packing boxes are of the right size

Experts say that it is not advisable to have more than 2 cm of space between the product and the packaging. Therefore, it is better to choose small boxes, not only because of the more compact packaging, but also because of the lower costs of purchasing and shipping products. Remove excess layers and labels

3. Remove excessive layers and labels

Each layer of cardboard, foam, etc., which is added to the packaging increases the cost. If the product really needs strong protection, consider replacing more lighter layers, for one more compact and sturdier. Also limit the number of labels, so it is recommended to stick one on the outside of the box and one on the inside.

4. Buy plastic or textile/composite straps in large quantities

Find out which suppliers offer you a discount when you purchase them. This does not always mean that purchases are made at the largest suppliers. It often happens that small packing material suppliers, which have developed good relations with their suppliers, are the ones that offer the possibility of the biggest discounts.

5. Reduce labor costs

It is always necessary to be striving to improve efficiency. This can be achieved by streamlining processes, maintaining tools and equipment, and continuing training for workers.

6. Re-use what is possible

With careful planning, many packaging materials can be reused. In this case, it is also necessary to take into account the material that we receive together with the raw materials for the manufacture of our products, and not only the one that goes with the product to the customer.

7. Maintain tools and equipment

Implement a preventive maintenance program for packaging, equipment, and tools. Establish a monitoring schedule and set up a maintenance and documentation tracking system. You create procedures for reporting problems and possible problems. It is also important to invest in the stock of spare parts that you need most often.

8. Consider the “Purchase Repurchase” and “Used Over New” System

Where possible, refurbish old equipment or buy used. This kind of choice can be good if the equipment is not the key to doing business. It is best to judge yourself whether packing equipment is the key to the business and the quality of your products.

9. Pay attention to price changes

Prices of products such as stretch foil and steel strips can fluctuate significantly from month to month. If you do not devote attention to this kind of price fluctuations, it can quickly happen that the costs increase. This is also one of the key reasons for dealing with a supplier that you trust. Thus, the risks are lower.

10. Find a supplier that offers everything you need

A reliable, experienced and professional supplier of packing material can save you a lot of money. He needs to know what he has available and advise you on the choice of his products that meet your needs. It is good to choose such a supplier, with which you intend to participate for a longer period of time, as it better sees your business and your needs. batterystrapping.com is international supplier and we offers all the necessary tools and straps for packing.

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When plastic (PP) polypropylene strap and (PET) polyester strap was invented and used for packaging, they almost completely replaced the steel strap packing. In particular, it was replaced where there was no substitute for packing with a steel band. With the development of plastic strips, the possibilities for a better and more efficient packaging have increased. The differences between these two are described below.

The essential difference between steel and plastic tape

Elongation is not a key feature of the steel strip. In contrast, the plastic tape has a greater elongation at a certain interval. A key feature of the plastic tape is its ability to return back to its original shape. After we have carried out some tension, the question is, to what extent can the tape from the elongated shape return to its original origin?

Wood loading is a good example of the transition to use from steel to plastic packaging. It is true that, in this case, the steel strap is more effective, since it has higher sustainable power in securing heavier loads, but the plastic tape is the one that quickly returns to its original shape after it has been pulled out. For this reason, which also represents the key difference between one and the other tape, the latter tape would be more effective for the above example. Taking into account the property of elasticity, therefore, the load as wood is more suitable for packaging with plastic tape. Namely, it has a greater possibility of adjusting the elasticity than a steel strip, the characteristic of which is elasticity, which does not include the possibility of extreme elongation and returns to its original shape. To summarize above, the steel strip is more susceptible to tearing down and becoming loose when transporting goods. In this case, the goods remain unprotected. It is true that steel strips can withstand more weight, but in many cases, the elasticity of the tape is a more important factor than the plastic tape.

The transition from steel to plastic strapping

Packaging with plastic tapes do not have such a long historical tradition as it is packed with steel. With the development of technology, this transition is becoming ever faster. Thus, in view of the production of more modern tools and the discovery of new packaging options, the plastic tape will completely outgrow the steel in a short time. Most leading manufacturers recognize that the transition from one tape to another is inevitable today.

Understanding elongation, tension, and recovery possibilities

To understand the above words, it is necessary to understand the conditions for using the straps. The tension of the tape is reflected when we drag it or perform a certain pressure on it. When it is stretched to a certain point, it begins to lengthen and stretch. Once delved, the only question is whether it will return to its original form. The ability of the elasticity of the tape is reflected by the highest possible point of expansion, from which the tape can still recover and not lose its shape (this is also referred to as the working area of the tape, or otherwise said the range of stamina endurance).

Learn more about the work area of the plastic PP and plastic PET strap

The working area of the tape varies considerably from strip to strip. It shows the best performance when using a single tape. It shows the highest voltage potential, where the elongation of the tape is maximum. At the same time, the elongation is still sufficient so that the tape returns to its original shape.

Learn more about returning the plastic PET and PP strap to the original shape (elasticity)

The possibility of returning to the original shape depends mainly on the material from which the tape is made, the size of the tension that is being applied to it and the lengths of this voltage. If it’s a short-lived voltage, the tape recovery option is much larger. For a longer period of time, then, on the tape, we execute the voltage, the smaller the possibility of restoring it back to the initial state. Here is one of the best candidates (ie those who, after a long time of tension, obtain the original shape the fastest), a straight plastic pocket tape.

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• attaching items to pallets, crates …
• ensuring uniform loading and packing of glass, wood and metal parts
• closing boxes and packages
• reinforcement of wooden boxes, crates or boxes of other materials
• secure items

Steel is the strongest and has the highest tensile strength, therefore the packaging is very reliable with it. It is available in different widths and thicknesses, but it also varies in quality. Steel is mainly used for packaging products that are sharp and hot. When deciding on which tape would be used when packaging your products and you have in mind steel, ask yourself:

• Is the load heavy and stable?
• Will the products travel long distances?
• Will they need to be downloaded and unloaded before downloading them

If the answer to these three questions is positive, then the steel or composite or PET strap is the right choice for you.

Plastic strips are more suitable for easier loads. They are available in different widths, lengths, and polymers. These ribbons offer a greater elongation, but their disadvantage is that they can tear apart at an excessive load. Nevertheless, the polyester fabric for packaging in many industries is the best alternative to steel straps. Polyester (PET), for example, provides excellent tension in the rigid load, and at the same time, the tape is very slowly worn. It is necessary to distinguish between plastic and polyester strips. In spite of specific differences, plastic straps are called “poly-bonds”. The following facts will teach you to distinguish them. The first is that the polyester tape is smoother, the other is that it can withstand higher tension.

Since packaging products have been packed for many years, the packing tape has also been developed with the simultaneous development of the packaging. However, it should be emphasized that the best and most widely used straps are steel and plastic straps. Each of them has its own advantages and disadvantages, so it is wise to determine which one is better suited to your needs before packing. It is more difficult to say that one is better than the other since each of them has both its advantages and weaknesses. Their quality may also vary from supplier to supplier, so it is a good idea to know all the features of the tape they offer and compare it with the cargo and products for which the strap will be used before buying.

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