Use-Case – ELECTRA M Series Tensioner and Sealer

The Challenge

A steel service center located in Linz processes about 280 slit coils and sheet bundles every day over two shifts. Strapping was handled using a combination of manual steel tensioners and older pneumatic sealers connected to overhead air hoses.

Each coil needed several straps, and operators had to frequently switch tools, especially when alternating between 19 mm and 32 mm steel strapping. Air hoses created tripping risks, and workers experienced wrist and shoulder fatigue from manual tensioning. Unexpected downtime from damaged air hoses and leaking fittings resulted in 35–40 minutes of lost production per shift.

Manual Process

The previous method combined manual tensioning and pneumatic sealing at each packaging station. One operator spent most of the workday strapping, with overtime required during busy periods.

Before Automation:

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

Additionally, leaks and failures in the air lines led to about 30 minutes/day of lost time over two shifts. Maintenance teams spent roughly 1 hour/week repairing leaks and replacing pneumatic tool fittings.

Automated Solution

The facility upgraded to the ELECTRA M Series Tensioner and Sealer, a battery-powered steel strapping tool that delivers up to 7500 N of strap tension and a tensioning speed of 3 m/min. The Makita 18 V lithium-ion battery, which recharges in 20 minutes, enabled continuous use with a simple battery rotation schedule.

Air hoses were removed from the main strapping area, and operators now use a single cordless tool for both tensioning and double-notch sealing. The lightweight 5 kg design and precise, repeatable tensioning greatly reduced physical strain and improved strap consistency.

After Installing ELECTRA M Series Tensioner and Sealer:

• The machine runs at 60% of its maximum output for increased reliability
• New cycle time: 0.95 minutes/unit (faster tensioning and built-in sealing)
• Total time per day: 280 × 0.95 = 266 minutes ≈ 4.4 hours/day
• Labor cost: 4.4 hours × €25/hour ≈ €110/day
• Quality improvement: rework dropped to 1 strap/day, with uniform tension and double-notch seals

Battery swaps were coordinated with breaks, so the 20-minute rapid charge did not interrupt productive time. Removing air hoses also eliminated the previous 30 minutes/day of air-related downtime.

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 (about 2 months)

Conclusion

By switching from manual and pneumatic steel tools to the ELECTRA M Series Tensioner and Sealer, the steel service center reduced strapping labor time by approximately 45% and eliminated the need for shop air at the packaging line. Consistent tensioning up to 7500 N and integrated sealing minimized rework and improved both ergonomics and safety.

“Moving to the ELECTRA M Series eliminated 8-hour days of manual and pneumatic strapping, cutting our time to about 4.5 hours and saving us around €108 daily. With a payback of roughly 45 days and no more air hose problems on the shop floor, this tool quickly became our go-to for all 280 coils we strap each day.” — Markus H., Packaging Supervisor, Linz Steel Service Center (Austria)