Use-Case – Pallet Strap Feeder B190

The Challenge

A retail distribution centre near Graz processes approximately 350 palletised consignments each day, all secured using PP and PET strapping. Previously, staff were required to bend or kneel to manually thread strapping beneath pallets—a method that was both time-consuming and physically strenuous.

The average time needed to feed strapping under a pallet had risen to over one minute per pallet, resulting in congestion at the despatch lanes. Additionally, the site recorded four to five minor back and knee injuries annually related to strapping, increasing indirect costs and prompting concern from the safety committee.

Manual Process

Prior to the introduction of the Pallet Strap Feeder B190, operators relied on the traditional “hand push” technique. This involved crouching down, attempting to push the naturally curved strap beneath the pallet, and then walking around to collect it. Strapping would often catch on boards or become misaligned, necessitating rethreading.

Before Automation:

• Daily throughput: 350 pallets per day
• Cycle time per pallet (under-pallet threading only): 60 seconds
• Total daily time: 350 × 60 = 21,000 seconds ≈ 350 minutes (5.8 hours per day)
• Labour cost: 5.8 hours × €25 per hour ≈ €144 per day
• Rework/issues: Approximately 10% of pallets required rethreading due to snagged or misaligned strapping

This slow and ergonomically poor process occupied one full-time operator during busy periods. Supervisors also estimated indirect costs of around €1,500 per year from minor musculoskeletal injuries and related staff absence.

Automated Solution

To enhance ergonomics and efficiency without replacing existing manual and battery-powered strapping tools, the site implemented the Pallet Strap Feeder B190 across all outbound lanes. While still a manual device, it effectively “automates” the under-pallet threading process by guiding the strap with a flexible 1,900 mm rod and polyurethane clip, allowing operators to remain upright.

After Installing Pallet Strap Feeder B190:

• Device operates at 60% of its maximum output for consistent performance
• Revised cycle time: 24 seconds per pallet (compared to 60 seconds previously)
• Total daily time: 350 × 24 = 8,400 seconds ≈ 140 minutes (2.3 hours per day)
• Labour cost: 2.3 hours × €25 per hour ≈ €58 per day
• Quality improvement: Rethreading rate reduced from 10% to under 2%, with staff able to remain standing throughout

The B190’s curved head and flexible rod enable strapping to pass smoothly beneath pallet decks on the first attempt. One operator can now manage several lanes, and the health and safety team observed a marked reduction in complaints regarding knee and lower back discomfort within the first quarter.

ROI Calculation

Investment:
Machine price: €69
Daily savings: (€144 − €58) = €86 per day
Monthly savings (22 working days): €86 × 22 = €1,892 per month
Payback period: €69 ÷ €86 per day ≈ 0.8 days (less than one working day)

Even with a cautious estimate of only €83 per day in net savings after accounting for change management and occasional low-volume days, the payback period remains well under a week. Further intangible benefits include a lower risk of injury, fewer interruptions due to rethreading, and a smoother outbound process.

Conclusion

By integrating the cost-effective Pallet Strap Feeder B190 into existing strapping stations, the Graz distribution centre reduced under-pallet threading time by approximately 60% and cut daily labour from 5.8 to 2.3 hours. With daily savings in the €80–€90 range, the tool recouped its cost within the first week of use, whilst also enhancing ergonomics.

“With the B190 we have reduced under-pallet threading from nearly six hours to just over two hours per day and are saving around €80 in labour costs each shift. The fact that staff can remain standing has also brought strapping-related complaints down to almost none.” — Sara T., Warehouse Manager, Graz Distribution Centre (Austria)