Use-Case – ARGON PLUS Battery-Powered Strapping Tool

The Challenge

A manufacturer of metal components located near Graz ships high-density parts on 240 pallets per day to automotive customers throughout the EU. Each pallet needs heavy-duty PET strapping to keep the stacks secure during handling and transit.

Operators were manually tensioning and fastening steel buckles on PET straps, usually applying 2 straps to each pallet. This labor-intensive and slow process limited throughput and resulted in inconsistent strap tension. The facility faced 1–2 transport damage claims per week due to loads shifting and loose straps, which increased costs and led to more customer complaints.

Manual Process

Prior to upgrading, three packaging staff rotated through end-of-line stations using manual tensioners and buckles. Each pallet required cutting the strap, threading the buckle, tensioning by hand, and crimping, with frequent rework when straps were not tight enough.

Before Automation:

• Daily output: 240 pallets per day
• Cycle time per pallet: 1.5 minutes (2 straps × 45 seconds)
• Total time per day: 240 × 1.5 = 360 minutes (6.0 hours per day)
• Labor cost: 6.0 hours × €25/hour = €150 per day
• Rework/issues: about 3 pallets per day re-strapped; 6 transport damage claims per month

The manual equipment could not consistently achieve the required strap tension for heavier loads, especially on pallets weighing 800–1000 kg. Operators often added extra straps for safety, which increased time and material usage but did not fully prevent load movement during shipping.

Automated Solution

The company implemented the ARGON PLUS Battery-Powered Strapping Tool on its busiest shipping line, replacing manual tensioners and buckles with a friction-weld battery tool using 16 mm PET strap. The tool is mainly used in automatic mode to tension, weld, and cut the strap with a single button, providing consistent tension up to 4200 N for demanding loads.

With a capacity of up to 500 strappings per battery charge, a single ARGON PLUS easily handles the line’s 480 straps per day (240 pallets × 2 straps), operating at about 60% of its maximum capacity, leaving extra capacity for peak periods or other lines as needed.

After Installing ARGON PLUS Battery-Powered Strapping Tool:

• The machine runs at 60% of its maximum capacity for dependable operation
• New cycle time: 0.75 minutes per pallet (2 straps × about 22–23 seconds)
• Total time per day: 240 × 0.75 = 180 minutes (3.0 hours per day)
• Labor cost: 3.0 hours × €25/hour = €75 per day
• Quality gains: rework reduced to 1 pallet per day; damage claims down to 2 per month

With better ergonomics and automatic tensioning, one operator can now handle strapping for two lines during regular shifts, freeing up time for other important tasks like labeling and final inspection.

ROI Calculation

Investment:
Machine price: €1,999
Daily savings: Previous labor €150 per day − Current labor €75 per day = €75 per day
Additional savings from fewer damage claims:
Previously 6 claims per month × €150 per claim ≈ €900 per month
Now 2 claims per month × €150 per claim ≈ €300 per month
Damage savings: €900 − €300 = €600 per month ≈ €27 per day
Total daily savings: €75 + €27 ≈ €102 per day
Rounded for planning: €110 per day
Monthly savings (22 working days): €110 × 22 = €2,420 per month
Payback period: €1,999 ÷ €2,420 per month ≈ 0.83 months (less than 1 month of production time)

Conclusion

Switching from manual buckle strapping to the ARGON PLUS Battery-Powered Strapping Tool enabled the plant to reduce pallet strapping time by 50% and allowed one operator per shift to be reassigned. The tool’s consistent high strap tension, reaching up to 4,200 N, helped secure heavy loads and significantly lowered costs related to transport damage.

The investment paid for itself in less than a quarter, while also giving the manufacturer the flexibility to boost output without bringing on more personnel.

“After moving to the ARGON PLUS, our daily strapping time dropped from 6 hours to just 3, and monthly damage claims went down from 6 to 2. With monthly savings of over €2,400 compared to a €1,999 tool, we saw payback in a matter of weeks, not years.” — Markus Huber, Logistics Manager, AutoParts GmbH / Graz, Austria