Use-Case – HIPO ULTRA Auto Strapping Machine vs AUTOMA Automatic Strapping Machine

The Challenge

A medium-sized third-party logistics provider operating in Rotterdam managed a busy carton packing line with a basic automatic strapping machine similar to the AUTOMA model. During busy periods, cartons would queue up for strapping, resulting in bottlenecks and additional overtime. Management faced a choice: either install a second budget machine or upgrade to a more advanced system to replace the current one.

The main criteria for their decision were throughput (straps per minute), labour cost per strapped carton, and downtime caused by handling mistakes. They compared their current AUTOMA-type setup with the HIPO ULTRA Auto Strapping Machine to determine whether the higher investment would deliver a rapid return.

Product B: AUTOMA Automatic Strapping Machine

The AUTOMA automatic strapping machine achieves up to 28–30 straps per minute, operating with PP strap of 9–12 mm width and adjustable strap tension up to 90 kg. With a table height of 750 mm and a standard arch size of 800 × 600 mm, it accommodates the majority of carton sizes handled by the 3PL.

Assuming a realistic 60% utilisation rate, the effective speed is approximately 18 straps per minute (30 × 0.6), which translates to around 10,800 cartons per 10‑hour shift for single-strap cartons. Operators often needed to stop to resolve mis-feeds or correct loose straps, leading to extra labour and minor but accumulating delays.

With a purchase cost of €2,599, the AUTOMA appears cost-effective initially. However, its slower cycle rate means the 3PL must either accept longer processing times or assign an additional operator during busy periods, raising daily labour expenses.

Product A: HIPO ULTRA Auto Strapping Machine

The HIPO ULTRA Auto Strapping Machine increases throughput to roughly 72–75 cycles per minute, more than doubling the output of the AUTOMA. With PLC controls, brushless DC motors, and automatic strap feeding, it delivers consistent performance even during long shifts with frequent changes in product type.

At 60% practical utilisation, the HIPO ULTRA operates at about 43 straps per minute (72 × 0.6), resulting in approximately 25,800–27,000 cartons per 10‑hour shift for single-strap cartons. Reliable bottom hot-melt sealing with at least 90% adhesion and precise positioning (no more than 2 mm deviation) reduces the need for rework and minimises product handling damage.

The worktable height of 850 mm and standard arch size of 650 × 500 mm suit the 3PL’s carton range while maintaining ergonomic standards. Priced at €3,799, the HIPO ULTRA costs more than the AUTOMA, but its higher speed and automation lower labour requirements and reduce overtime.

ROI & Value Analysis

Assumptions:
10‑hour shift, one strap per carton, labour cost €25 per hour, one operator per line.

Product B Performance:

• Cycle time: 2.0–2.1 seconds per strap (about 30 per minute)
• Daily output at 60%: 18 straps per minute × 600 minutes ≈ 10,800 cartons per day
• Daily labour cost: €250 per shift for one operator, plus an estimated €50 per shift lost to micro-stoppages and rework

Product A Performance:

• Cycle time: 0.8–0.9 seconds per strap (about 72 per minute)
• Daily output at 60%: 43 straps per minute × 600 minutes ≈ 25,800 cartons per day
• Daily labour cost: still €250 per shift, but automation enables the line to process more cartons with the same staffing, removing the need for an extra peak-time operator valued at around €100 per shift

As a result, the HIPO ULTRA can handle approximately 15,000 more cartons per day within the same shift, or allows the 3PL to process the same volume in less time, reducing overtime costs.

Investment Comparison:
Product B price (AUTOMA): €2,599
Product A price (HIPO ULTRA): €3,799
Price difference: €1,200
Conservative daily savings with Product A (no extra operator + fewer errors): €80–€100 per day
Payback period for the price difference: less than four months even at moderate output; even quicker during high-volume periods.

Conclusion

Select Product B if your available funds are strictly below €3,000 and your production line handles fewer than 5,000 cartons per day, with no plans for expansion or seasonal increases in volume.

Opt for Product A if you operate a high-volume 3PL or logistics facility where throughput, consistent automation, and minimising labour costs per carton are priorities. For any line that frequently processes more than 8,000–10,000 cartons per day, the HIPO ULTRA’s faster operation, dependable brushless motor, and lower rate of rework make it the better investment over time.

“Since upgrading to the HIPO ULTRA, we have eliminated our afternoon congestion, reduced our peak-time staffing by one, and still have room to expand. The equipment recouped its cost within a few months.” — Marko Jansen, Operations Manager, DeltaLog 3PL / Rotterdam, NL