Use-Case – AKU-STEEL DUO Battery Strapping Tool

The Challenge

A steel manufacturing facility near Maribor prepares and dispatches cut and bundled profiles to building sites throughout Central Europe. Each day, the site secures approximately 180 pallets using robust steel strap prior to loading onto lorries.

Previously, staff relied solely on manual ratchet tensioners and hand sealers. Every pallet required considerable manual effort to apply the correct strap tension and seal, resulting in slow processing speeds and operator fatigue. As demand increased, the plant experienced regular overtime, uneven strap tension, and occasional load movement during transport, all of which led to increased costs and delays.

Manual Process

Before the AKU-STEEL DUO was introduced, all strapping tasks were performed with manual steel strapping equipment.

Prior to Automation:

• Daily output: 180 pallets per day
• Time per pallet: 10 minutes (including strap placement, manual tensioning, sealing, and cutting)
• Total time per day: 180 × 10 = 1,800 minutes (30.0 hours per day)
• Labour expense: 30.0 hours per day × €25 per hour = €750 per day
• Rework/issues: Roughly 3 pallets per day required re-strapping due to insufficient strap tension or failed seals

This process demanded more than one full-time worker per shift dedicated solely to strapping. Overtime became commonplace, and the physical demands increased the likelihood of injury and inconsistent results.

Automated Solution

The facility adopted the AKU-STEEL DUO Battery Strapping Tool set, which includes both a battery-powered tensioner and sealer for steel strap. These tools were deployed on the main outbound line, replacing the previous manual ratchets and sealers.

Following the Introduction of the AKU-STEEL DUO Battery Strapping Tool:

• The equipment is run at 60% of its maximum output to ensure reliability
• Revised cycle time: 3.2 minutes per pallet (swift battery-powered tensioning and sealing)
• Total time per day: 180 × 3.2 = 576 minutes (9.6 hours per day)
• Labour expense: 9.6 hours per day × €25 per hour = €240 per day
• Quality gains: Rework reduced from 3 pallets per day to fewer than 1 pallet per day thanks to consistently high-tension seals

The lighter, ergonomically designed battery tools eased physical workload and enabled a single operator to manage all strapping on the line without the need for overtime.

ROI Calculation

Investment:
Equipment cost: €2,999
Daily savings: Manual labour €750 per day − Automated labour €240 per day = €510 per day
Monthly savings (22 working days): €510 per day × 22 days = €11,220 per month
Payback period: €2,999 ÷ €510 per day ≈ 5.9 days
Payback period: less than 6 working days (≈0.3 months)

Even when factoring in setup, training, and occasional maintenance, and conservatively estimating only €100 per day in net savings over time, the return on investment remains very rapid:
Revised daily savings: €100 per day
Monthly savings (22 days): €100 × 22 = €2,200 per month
Payback period: €2,999 ÷ €100 per day ≈ 30 days
Payback period: around 1.5 months of operation

Conclusion

By upgrading from manual ratchet tools to the AKU-STEEL DUO Battery Strapping Tool, the steel plant in Slovenia reduced daily strapping time from 30.0 to 9.6 hours and cut labour costs by approximately €510 per day. Strapping quality improved, rework was minimised, and staff reported significantly less fatigue during busy shifts.

“With the AKU-STEEL DUO we cut strapping time by over 60% and freed up nearly a full operator per shift. Saving more than €100 per day in labour while achieving better strap consistency meant the investment paid for itself in well under three months.” — Marko K., Production Manager, Maribor Steel Works / Slovenia