Use Case – ITI 71 Battery Strapping Tool

The Challenge

A coated steel coil manufacturer near Linz handles approximately 160 coils per day, many of which are oversized and have highly sensitive surfaces. Previously, coils were secured using 32 mm steel strap with manual tensioners and separate sealing tools.

This process was both slow and hazardous. Each coil required four straps, and the entire operation—including managing sharp strap ends and applying seals—took about 9 minutes per coil. Monthly quality checks revealed that about 6% of coils arrived with edge marks or scratches on the coating, often caused by steel strap damage or rust transfer. In addition, three minor hand injuries from sharp steel strap were reported over the year, and costs for disposing of steel scrap continued to rise.

The quality and HSE departments requested a safer method that would keep the coils secure while removing the risk of corrosion from steel strapping on coated products.

The Solution

After evaluating several options, the facility chose the ITI 71 Battery Strapping Tool paired with 32–40 mm composite strap for all coated coil lines. The ITI 71 delivers up to 11,000 N strap tension, matching the holding strength of the previous steel strap, while the wide textile/composite strap helps protect delicate edges.

The ITI 71 is typically operated at about 60% of its maximum tension to ensure both security and optimal strap elongation. Operators use the built-in cutting unit to tension and cut the strap in one motion, removing the need for separate cutters and metal seals. Each tool is equipped with two 18V Li-Ion batteries (providing approximately 400 cycles per charge), supporting continuous operation throughout a shift with quick 40-minute recharging.

ROI Calculation

Before – Steel strap & manual tools:

• Daily output: 160 coils × 4 straps = 640 straps per day
• Average strapping time: 9 min per coil → 160 × 9 = 1,440 min per day (24 hours of labor)
• Quality issues: 6% of 160 = 10 coils per month claimed, average loss €350 per coil → €3,500 per month
• Steel strap, seals, and scrap disposal (extra vs. textile): about €0.30 per coil → €1,050 per year (a modest but real cost)

After – ITI 71 with composite strap:

• New strapping time: around 5 min per coil → 160 × 5 = 800 min per day (13.3 hours)
  Labor savings: 24 h − 13.3 h ≈ 10.7 hours per day → at €18/h ≈ €190 per day or about €3,800 per month
• Damage rate reduced to 2% of coils: 3–4 coils per month × €350 ≈ €1,050 per month
  Improvement over previous: €3,500 − €1,050 = €2,450 per month saved
• Total monthly savings (labor + damage + materials): approximately €6,300 per month

Investment:
2 × ITI 71 tools (each with 2 batteries & charger): €2,439 × 2 = €4,878
Simple payback: €4,878 ÷ €6,300 ≈ less than 1 month
Even after factoring in additional composite strap costs and contingencies, the facility conservatively estimated ROI at under 5 months for both lines combined.

Results

By switching from steel strap to wide composite strap with the ITI 71, strapping time per coil was nearly cut in half, and surface damage and corrosion complaints were greatly reduced. Operators report that handling is easier and safer, with less fatigue, while quality and HSE teams achieved their goals without sacrificing load security.

“The ITI 71 enabled us to move away from steel strap on coated coils without any compromise in security. We have fewer claims, faster packing, and our operators much prefer working with textile strap instead of sharp steel.” — Markus Huber, Packaging Manager, StahlCoil GmbH / Linz, Austria