What banding tools do and how they work

Strapping tools, also called banding tools, tension the strap around the load, join the ends and cut the strap from the coil. The drive can be by hand, battery or compressed air. Each tool is built for a certain strap type and width.

The joint depends on the strap. Battery tools weld PET and PP strap by friction, the pneumatic AIR19 welds PET strap, and the manual PPST-13/16 joins PP strap with a metal seal. Steel strap is joined with a seal, clip or by a sealless tool. Textile and composite strap use a wire buckle. The strap itself is in the Strapping bands category.

Not every tool does all three: a tensioner such as the ITI 71 tensions and cuts textile and composite strap, and a wire buckle holds the joint.

The drive type determines where and how the tool can be used. Manual tools do not require any power source, so they are suitable for locations without electricity or compressed air. Battery tools operate without a hose or cable, allowing you to move freely around the warehouse or production floor. Pneumatic tools need a compressed-air line at the workstation, so they suit packing places that already have one.

Before you use the tool, pull the strap around the load as tight as you can by hand. The tool then needs less time to tension the strap and, on a battery tool, less charge.

After each strap is applied, check the joint. A friction weld should cover the full width of the strap, a metal seal should be crimped firmly, and a sealless steel joint should be hooked in and cleanly sheared. If the joint is not formed correctly, cut the strap off and strap the load again. Oil, grease or water on the strap can stop a friction weld from holding, so keep the strap clean and dry.

Battery powered strapping tool models and their uses

Battery strapping tools work without a hose or cable. For PET and PP strap from 9 to 19 mm, models include NEO2, NEO Plus, GT ONE, SIAT VIPER and Signode BXT3; the TES EXTREME is for PET strap 19–25 mm. The ITI 71 is a battery tensioner for textile and composite strap 16–40 mm.

For steel strap, the AKU-STEEL DUO and ELECTRA M SERIES are battery powered sets for 19, 25 or 32 mm. These tools tension, join and cut the strap. Some models include one or two batteries and a charger.

By width, the NEO2 is for 9–16 mm strap, the SIAT VIPER for 9, 12 or 16 mm and the GT ONE for 10–16 mm. The NEO Plus is for 16–19 mm, and the Signode BXT3 comes in three versions for 9–19 mm. The TES EXTREME is made for PET strap 19–25 mm.

These battery powered strapping tool models weld the strap by friction, which means you do not need to buy metal seals for each joint. The only running cost is the strap itself. Some tools, such as the NEO Plus and TES EXTREME, come with two batteries and a charger. One battery charges while the other works.

The ITI 71 tensions textile and composite strap up to 11000 N; the joint is a wire buckle, which must match the strap width. Some tools, like the GT ONE, have a soft mode with 500 N tension for light or fragile packs.

A friction weld does not keep the full strength of the strap. On the NEO2, the joint holds about 75 percent of the strap strength. The SIAT VIPER reaches 75 to 85 percent. So a strap around the load is only as strong as its joint.

On the NEO Plus, the tension is set on the display in 7 gears, not as a force: gear 1 is about 600 N and gear 7 about 4000 N. Note which gear works for each type of pack and use it on every shift.

Subcategories of strapping tools and what is in each

To use the table, first find the strap material and width you use in the Strap column. Then read the subcategory in the first column of that row. Open the subcategory to see all matching products. The Examples column lists a few typical products for each subcategory, but not every model is shown there. For instance, PET strap 16 mm wide is in the rows for battery strapping tools and pneumatic banding tools.

Manual and pneumatic strapping tools for every strap type

Manual strapping tools include the PPST-13/16 for PP strap with metal seals, the A3, BO-51 and A4, each a sealless steel banding tool, and a manual tensioner for textile and composite strap in three sizes. The B190 pallet threading tool pushes the strap under the pallet with a 1900 mm flexible rod, so nobody kneels at every pallet.

Pneumatic banding tools include the AIR19 for PET and PP strap 13–19 mm, the AIR Metal for steel strap 19–32 mm, and the AIR DUO32 for steel strap 19, 25 or 32 mm. All pneumatic tools require compressed air.

Manual tools do not require a battery or compressed air, so they are practical for locations where power is not available or only a few straps are applied each day.

The AIR19 joins PET and PP strap with a friction weld, so no seals are needed. The AIR Metal joins steel strap with a steel clip. The AIR DUO32, a tensioner and sealer, joins steel strap with a seal.

No manual tool in this category is made for PET strap. The PPST-13/16 is for PP strap only, so if you need to strap PET, use a battery tool such as the NEO2 or the pneumatic AIR19.

On the A3, the upper strap of a sealless joint should be hooked 1 to 1.5 mm, at most 2 mm, into the lower strap. Pneumatic tools need a filter, a regulator and a lubricator in the air line. The AIR DUO32 set is made for one strap width only, so if you use two widths, you need a separate set for each.

Pallet strapping kits, carts and seals

Pallet strapping kits combine a tool, strap and a strapping cart in one order. Banding carts dispense PET, PP, cord, textile or steel strap coils, matching the core size and strap type. Strapping seals include metal seals for PP strap, clips for steel strap and wire buckles for textile and composite strap.

The kits hold a battery, manual or pneumatic tool with strap and a cart.

Battery kits such as the NEO2 kit include the battery and charger. Kits with the PPST-13/16 add PP strap and metal seals, while the CORD kit is for composite strap and includes a manual tensioner, two coils of composite strap, wire buckles and a dispenser cart. The AIR19 kit adds PET strap 15.5 mm and a strapping cart; the tool still needs a compressed-air line.

Banding carts are designed to hold the strap coil and let the strap off smoothly without tangles. The cart must fit the coil’s core size: 405/406 mm for PET and PP coils, 200 mm for cord and PP coils (HC2), 76 mm for textile strap, and the HS5 for steel strap coils. Using the correct cart prevents the coil from unwinding on its own and keeps the strap organized during work.

Strapping seals are chosen to match the strap width and type. Metal seals are available in 13 mm or 16 mm for PP strap, steel strap clips are 16 x 40 mm for manual strapping, and pneumatic clips come in 16 x 40, 19 x 57, 25 x 57 and 32 x 57 mm sizes for pneumatic steel strapping. Wire buckles are used for textile and composite strap and must match the strap width. Each joint requires one seal, clip or buckle, so you should order enough for the number of straps you plan to apply.

Hand, battery or air: which drive fits

Strapping tools use three drives: hand, battery or compressed air. Manual strapping tools suit a few straps a day and places without power or air. Battery strapping tools, such as NEO2 or GT ONE, work at the load and stop at the set tension. Pneumatic models like AIR19 need a compressed-air line but no charging. When the straps a day outgrow hand tools, an automatic banding machine straps each pack by itself; these are in the strapping machines category.

If you only need to apply a few straps a day or work in a place without power or compressed air, a manual tool is the practical choice.

When you have to strap many pallets or bundles each day and the work takes place at different locations, a battery tool is more suitable. Battery strapping tools like the NEO2 or GT ONE are portable and operate without a hose or cable. They go directly to the load, and you can set the tension so the tool stops automatically when the set value is reached.

If your packing line already has a compressed-air line installed, pneumatic tools are a good fit. Pneumatic models such as the AIR19 or AIR Metal do not need batteries, so there is no downtime for charging.

A tool goes to the load; a strapping machine needs the load brought to it.

For PP strap, the manual PPST-13/16 crimps a metal seal on every strap, so each pack takes seals and lever work. As the number of straps per day increases, this extra step and the cost of seals add up. A battery tool such as the NEO2 welds PP strap without seals.

Steel strap can be applied with all three drives. The manual A3 is made for 13, 16 or 19 mm steel strap and the A4 for strap 0.55 to 0.75 mm thick, both joining without seals. The battery AKU-STEEL DUO is for thicker steel strap, 0.8 to 1.2 mm, and the pneumatic AIR Metal and AIR DUO32 need a compressed-air line. The A3 and A4 are lever tools that need both hands on the tool.

For textile and composite strap, the manual tensioner comes in three sizes up to 50 mm for occasional use. The ITI 71 battery tensioner, for 16 to 40 mm, suits many straps a day. Upkeep depends on the drive: manual tools are cleaned and oiled, battery tools need charging and dry, frost-free battery storage, and pneumatic tools need the air line filter drained daily and the lubricator filled. Pneumatic tools need enough air volume as well as pressure.

Matching strapping tools, strap and cart

Before ordering, check the load, strap material and width. Strapping tools must match the strap: PET, PP, steel, textile or composite.

Seals, clips and buckles must fit the strap width. Each joint takes one. The dispenser cart must take the coil core.

Start by identifying the strap you use: the material, width and thickness. The tool you choose must be designed for that strap type and size. For example, if you use PET strap 16 mm wide, you need a tool that covers 16 mm PET, such as the NEO Plus. If your strap is steel, check that the tool is made for steel strap and matches the width, such as the AKU-STEEL DUO for 19, 25 or 32 mm steel strap.

Next, select the joint type that fits your process. Battery tools for PET and PP strap and the pneumatic AIR19 for PET strap weld the joint by friction, so you do not need to order seals. The manual PPST-13/16 uses a metal seal, so you must order seals in the correct width. For steel strap, you can choose a tool that uses a seal or clip, or a sealless tool such as the A3, BO-51 or A4. Textile and composite straps are joined with a wire buckle that matches the strap width.

Check the coil core size against the dispenser cart. PET and PP coils on a 405/406 mm core need the PET/PP dispenser cart. Cord and PP coils on a 200 mm core fit the HC2 cart. Textile strap rolls on a 76 mm core use the textile strap cart. Steel strap coils are used with the HS5 cart.

Count how many straps you apply each day and check if there is power or compressed air at the place where you strap the load.

Match the PET strap to the battery tool by both width and thickness. For example, 15.5 x 0.9 mm PET strap fits the NEO2 and GT ONE, 19 x 1.0 mm fits the NEO Plus, and 25 x 1.2 mm fits the TES EXTREME.

Clips must fit both the tool and the strap. Pneumatic clips are not for manual tools, and the 16 x 40 mm clips for manual strapping go with a manual tensioner and a sealer. Check the strap width against the cart as well. The PET/PP dispenser cart is made for strap 10–19 mm wide on a 405/406 mm core, and the PP strap of this shop is on a 406 mm core, so it fits this cart. The PET/PP dispenser cart and the HC2 have a brake, which keeps the coil from running on when the strap is pulled, and a box or tray for seals and a tool.

What affects the price of a strapping tool

The price of a strapping tool depends on the drive (manual, battery or pneumatic), the strap width and tension, and whether the tool comes with one or two batteries. For steel strap, some sets include a tensioner and a sealer. The running cost comes from the strap, seals, clips and buckles. The price is shown on each product card.

The main running cost is the strap itself. For tools that use a seal, clip or buckle, you need to order one per joint, which adds to the cost over time. On each product card, you will find a Get offer button to request a quote and an Add to inquiry button to collect several products into one request.

To work out the cost per strap, take the strap length around the pack plus the overlap and divide the coil length on the strap page by it. For example, a 19 x 1.0 mm PET coil holds 1000 meters. This gives you the number of straps per coil and, at one per joint, the number of seals, clips or buckles you need.

Seals, clips and buckles are sold by the box. For example, PP seals come in boxes of 1000 and pneumatic clips in boxes of 1000 (800 for 32 x 57 mm). Wear parts also belong to the running cost. On battery tools for plastic strap, the cutter, toothed plates and tension wheel are wear parts. On the AKU-STEEL DUO, the moving jaw and feed wheel are wear parts.

Working safely with strapping tools

When using strapping tools, wear gloves and eye protection. Stand to the side of the strap while tensioning. A tensioned strap can spring back when cut, so always cut it from the side with banding cutters. Edge protectors help prevent strap damage on sharp corners.

Never lift or pull a load by its strap. Keep the coil in a dispenser cart so it does not unwind on its own.

The edges of steel strap are sharp and can cause cuts if handled without protection. Eye protection is important because the strap can spring back when cut.

Stand to the side of the strap while it is being tensioned, not directly in line with it. This reduces the risk of injury if the strap breaks or slips during tensioning.

Cutting from the side keeps your body out of the path of the strap if it springs back.

Use edge protectors on sharp corners to prevent the strap from being damaged or cut by the load.

When you cut a tensioned steel strap, always hold the upper part, as the lower strap snaps forward. Keep your fingers out of the tension wheel area and never put your hand between the strap and the pack during tensioning. Never ship a load with a joint that is not formed correctly.

Plan for hearing protection where needed. The SIAT VIPER reaches about 96 dB(A) while welding, and the AIR19 manual asks for earmuffs where the noise is above 85 dB(A). If a strap jams in a battery tool, take the battery out first, then cut the strap free. When blowing dust out of a tool with compressed air, wear eye protection, as the dust is thrown toward your face.

Questions about strapping tools

Which tool should I use for steel strap?

For steel strap, use the AKU-STEEL DUO or ELECTRA M SERIES battery powered sets for 19, 25 or 32 mm, or the manual sealless A3, BO-51 or A4. Pneumatic tools AIR Metal and AIR DUO32 are also available for steel strap.

Do battery strapping tools need seals?

Battery strapping tools for PET and PP strap weld the strap by friction and do not need metal seals. For steel strap, both battery sets need seals: the AKU-STEEL DUO joins the strap with a steel seal and the ELECTRA M SERIES with a double-notch seal joint. The ITI 71 for textile and composite strap needs wire buckles.

What does a pallet strapping kit contain?

A pallet strapping kit contains a strapping tool, strap and a strapping cart. Some kits include a battery and charger, metal seals or wire buckles, depending on the tool and strap.

Which dispenser cart fits which coil?

The PET/PP dispenser cart fits PET and PP coils on a 405/406 mm core. The HC2 cart is for cord and PP coils on a 200 mm core. The textile strap cart fits textile rolls on a 76 mm core. The HS5 is for steel strap coils.