How banding tools work and what they do

Banding tools, also called strapping tools, tension the strap around your load, seal the ends, and cut the strap from the coil. They may be powered by hand, battery, or compressed air. Each tool is made for a specific strap type and width.

The way the strap is joined depends on the material. Battery powered strapping tool models weld PET and PP strap by friction. The pneumatic AIR19 welds PET strap, while the manual PPST-13/16 uses a metal seal for PP strap. Steel strap is joined with a seal, clip, or by a sealless tool. Textile and composite straps are secured with a wire buckle. You can find strapping material in the strapping material category.

Not all tools perform every function: for example, the ITI 71 is a tensioner that tensions and cuts textile and composite strap, while a wire buckle secures the joint.

The type of drive affects where and how you can use the tool. Manual strapping tools do not need any power source, making them ideal for locations without electricity or compressed air. Battery powered strapping tools work without hoses or cables, so you can move freely in your warehouse or production area. Pneumatic banding tools require a compressed air line at the workstation, so they are best for packing stations already equipped with air supply.

Before using a banding tool, pull the strap as tight as possible around the load by hand. This reduces the time needed for the tool to tension the strap and, for battery powered models, saves battery charge.

After applying each strap, inspect the joint. A friction weld should cover the entire strap width, a metal seal must be firmly crimped, and a sealless steel joint should be properly hooked and cleanly sheared. If the joint is not correct, cut off the strap and re-strap the load. Oil, grease, or water on the strap can prevent a friction weld from holding, so always keep the strap clean and dry.

Battery powered strapping tool models and their applications

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

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

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

These battery powered strapping tool models use friction welding, so you do not need to purchase metal seals for each joint. The only ongoing cost is the strap itself. Some tools, like NEO Plus and TES EXTREME, include two batteries and a charger, so you can charge one battery while using the other.

The ITI 71 applies up to 11,000 N of tension to textile and composite strap; the joint is made with a wire buckle that must match the strap width. Some tools, such as GT ONE, offer a soft mode with 500 N tension for lighter or more fragile packages.

A friction weld joint does not retain the full strength of the strap. For example, the NEO2 joint holds about 75% of the strap’s strength, while the SIAT VIPER achieves 75–85%. The strength of the strap around the load is limited by the joint.

On the NEO Plus, tension is set on the display in 7 gears, not as a force value: gear 1 is about 600 N, gear 7 about 4000 N. Record which gear works for each package type and use it consistently.

Banding tool subcategories and their contents

To use the table, first find your strap material and width in the Strap column. Then, check the subcategory in the first column of that row. Open the subcategory to view all matching products. The Examples column lists typical products for each subcategory, but not every model is shown. For example, PET strap 16 mm wide appears in both battery powered strapping tools and pneumatic banding tools.

Manual and pneumatic banding 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, which are all sealless steel banding tools, and a manual tensioner for textile and composite strap available in three sizes. The B190 pallet threading tool uses a 1900 mm flexible rod to push the strap under the pallet, so no one has to kneel at each 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 in 19, 25, or 32 mm widths. All pneumatic tools require a compressed-air supply.

Manual tools do not need a battery or compressed air, making them practical for locations without power or where 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 using a steel clip. The AIR DUO32, which is a tensioner and sealer, joins steel strap with a seal.

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

On the A3, the upper strap in a sealless joint should be hooked 1 to 1.5 mm, and no more than 2 mm, into the lower strap. Pneumatic tools require a filter, regulator, and lubricator in the air line. The AIR DUO32 set is made for only one strap width, so if you use two widths, you need a separate set for each.

Pallet strapping kits, carts and seals

Pallet strapping kits include a tool, strap, and a banding cart in one package. Banding carts are used to dispense PET, PP, cord, textile, or steel strap coils, and are matched to 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 include a battery, manual, or pneumatic tool, along with strap and a cart.

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

Banding carts are designed to hold the strap coil and dispense the strap smoothly without tangling. The cart must match 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 keeps the coil from unwinding by itself and keeps the strap organized during use.

Strapping seals must 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 fit the strap width. Each joint needs 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

Banding tools use three types of drive: hand, battery, or compressed air. Manual strapping tools are best for a few straps a day and places without power or air. Battery powered strapping tools, such as NEO2 or GT ONE, work at the load and stop at the set tension. Pneumatic models like AIR19 require a compressed-air line but do not need charging. When the number of straps per day is too high for hand tools, an automatic banding machine straps each pack by itself; you can find these in the strapping machines category.

If you only need to apply a few straps a day or work where there is no power or compressed air, a manual tool is the practical choice.

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

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

A tool is brought to the load, while a strapping machine requires the load to be brought to it.

For PP strap, the manual PPST-13/16 crimps a metal seal on every strap, so each pack needs seals and lever work. As the number of straps per day increases, this extra step and the cost of seals add up. A battery powered strapping tool like 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 require a compressed-air line. The A3 and A4 are lever tools that require both hands on the tool.

For textile and composite strap, the manual tensioner is available in three sizes up to 50 mm for occasional use. The ITI 71 battery tensioner, for 16 to 40 mm, is suitable for frequent use. Maintenance depends on the drive: manual tools need cleaning and oiling, battery tools require charging and dry, frost-free battery storage, and pneumatic tools need the air line filter drained daily and the lubricator filled. Pneumatic tools also need enough air volume as well as pressure.

Matching banding tools, strap, and cart

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

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

Start by identifying the strap you use: material, width, and thickness. The tool you select must be made 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, make sure 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, choose the joint type that fits your process. Battery powered strapping 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 like 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 location where you strap the load.

Match the PET strap to the battery powered strapping 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 be compatible with both your banding tools and the strapping material. Pneumatic clips are not suitable for manual tools, and the 16 x 40 mm clips for manual strapping are used with a manual tensioner and a sealer. Always check that the strap width matches your banding cart. The PET/PP dispenser cart is designed for strapping material 10–19 mm wide with a 405/406 mm core. The PP strap offered in this shop comes on a 406 mm core, so it fits this cart. Both the PET/PP dispenser cart and the HC2 model include a brake to prevent the coil from unwinding when you pull the strap, as well as a box or tray for storing strapping clips and your tool.

What determines the price of banding tools

The cost of a banding tool depends on the drive type (manual, battery powered, or pneumatic), the strap width and tension range, and whether the tool is supplied with one or two batteries. For metal strapping, some sets include both a tensioner and a sealer. Ongoing costs come from the strapping material, strapping clips, seals, and buckles. Each product card displays the price.

The main ongoing expense is the strapping material itself. For tools that use a seal, clip, or buckle, you will need one for every joint, which increases your long-term costs. Each product card features a Get offer button to request a quote and an Add to inquiry button so you can group several products into a single request.

To calculate the cost per strap, measure the length of strap needed to go around your package plus the overlap, then divide the coil length (as listed on the strap page) by this number. For example, a 19 x 1.0 mm PET coil contains 1,000 meters. This tells you how many straps you get per coil and, since you need one per joint, how many strapping clips, seals, or buckles you should order.

Seals, clips, and buckles are sold in boxes. For example, PP seals are packaged in boxes of 1,000, and pneumatic clips are also in boxes of 1,000 (800 for 32 x 57 mm size). Wear parts are another ongoing cost. For battery powered strapping tools used with plastic strap, the cutter, toothed plates, and tension wheel are considered wear parts. On the AKU-STEEL DUO, the moving jaw and feed wheel are wear parts.

Safe operation of banding tools

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

Never lift or move a load by its strapping. Keep the coil in a banding cart to prevent it from unwinding unexpectedly.

The edges of metal strapping are sharp and can cause injuries if handled without protection. Eye protection is essential, as the strap may spring back when cut.

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

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

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

When cutting a tensioned metal strap, always hold the upper section, as the lower part will snap forward. Keep your fingers away from the tension wheel area and never place your hand between the strap and the package during tensioning. Never send out a load with an improperly formed joint.

Plan for hearing protection where necessary. The SIAT VIPER produces about 96 dB(A) during welding, and the AIR19 manual recommends earmuffs if noise exceeds 85 dB(A). If a strap jams in a battery powered strapping tool, remove the battery before cutting the strap free. When using compressed air to clean dust from a tool, wear eye protection, as dust will be blown toward your face.

Frequently asked questions about banding tools

Which tool is suitable for metal strapping?

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

Do battery powered strapping tools require seals?

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

What is included in a pallet strapping kit?

A pallet strapping kit includes a banding tool, strapping material, and a banding cart. Some kits also come with a battery and charger, metal seals, or wire buckles, depending on the tool and strapping material.

Which dispenser cart matches which coil?

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