Use Case – ELECTRA M Series Tensioner and Sealer

The Challenge

A steel service centre in Linz processes approximately 280 slit coils and sheet bundles each day over two shifts. Strapping was previously carried out using a combination of manual steel tensioners and ageing pneumatic sealers attached to overhead air hoses.

Each coil required several straps, with frequent tool changes, particularly when alternating between 19 mm and 32 mm steel strapping. The routing of air hoses created tripping hazards, and operators experienced wrist and shoulder discomfort from manual tensioning. Unexpected stoppages caused by damaged air hoses and leaking connectors resulted in a total of 35–40 minutes of downtime per shift.

Manual Process

The previous method combined manual tensioning and pneumatic sealing at each packaging station. One operator spent the majority of their working day on strapping, with overtime required during busy periods.

Prior to Automation:

• Daily output: 280 strapped units per day
• Cycle time per unit: 1.7 minutes per unit (manual tensioning 1.2 min + positioning/sealing 0.5 min)
• Total daily time: 280 × 1.7 = 476 minutes ≈ 8.0 hours per day
• Labour cost: 8.0 hours × €25/hour = €200 per day
• Rework/issues: 4–5 straps per day needed re-tensioning or re-sealing due to uneven tension or misaligned seals

Additionally, air hose leaks and connector failures resulted in around 30 minutes per day of lost time across both shifts. Maintenance staff spent roughly 1 hour per week locating leaks and replacing fittings on the pneumatic tools.

Automated Solution

The centre introduced the ELECTRA M Series Tensioner and Sealer, a battery-powered steel strapping tool capable of up to 7,500 N strap tension and a tensioning speed of 3 m/min. The Makita 18 V lithium-ion battery, with a 20-minute recharge time, enabled uninterrupted operation through a straightforward battery rotation schedule.

Air hoses were removed from the main strapping area, and operators now apply tension and double-notch seal using a single cordless tool. The compact 5 kg design and precise, repeatable tensioning have greatly reduced physical strain and improved consistency in strap quality.

Following Installation of the ELECTRA M Series Tensioner and Sealer:

• The machine is run at 60% of its maximum capacity to ensure reliability
• Updated cycle time: 0.95 minutes per unit (quicker tensioning and integrated sealing)
• Total daily time: 280 × 0.95 = 266 minutes ≈ 4.4 hours per day
• Labour cost: 4.4 hours × €25/hour ≈ €110 per day
• Quality gains: rework reduced to 1 strap per day, with uniform tension and double-notch sealing

Battery changes were coordinated with break times, so the 20-minute rapid charge did not impact productive time. The removal of air hoses also eliminated the previous 30 minutes per day lost to air-related interruptions.

ROI Calculation

Investment:
Machine cost: €4,890
Daily savings: Labour: €200 − €110 = €90 per day
Downtime reduction: 0.5 hours per day × €25/hour ≈ €13 per day
Maintenance reduction: 1 hour per week × €25/hour ≈ €5 per day (allocated)
Total daily savings: €90 + €13 + €5 ≈ €108 per day
Monthly savings (22 working days): €108 × 22 = €2,376 per month
Payback period: €4,890 ÷ €108 per day ≈ 45 days (about 2 months)

Conclusion

By upgrading from manual and pneumatic steel tools to the ELECTRA M Series Tensioner and Sealer, the steel service centre reduced strapping labour time by approximately 45% and removed the reliance on compressed air at the packaging line. Consistent tensioning up to 7,500 N and integrated sealing have lowered rework rates and improved both ergonomics and safety.

“Switching to the ELECTRA M Series eliminated 8-hour days of manual and pneumatic strapping, reducing our process to around 4.5 hours and saving roughly €108 daily. With a payback of about 45 days and no further air hose problems on the shop floor, this tool rapidly became our standard for all 280 coils we strap each day.” — Markus H., Packaging Supervisor, Linz Steel Service Centre (Austria)