Use-Case – ITI 71 Battery Strapping Tool

The Challenge

A manufacturer of coated steel coils located near Linz handles approximately 160 coils each day, many of which are oversized and particularly sensitive to surface damage. Previously, coils were secured using 32 mm steel strap applied with manual tensioning tools and separate sealing devices.

This approach was both time-consuming and hazardous. Each coil required four straps, with the process taking roughly 9 minutes per coil, including the risks associated with handling sharp strap ends and fitting seals. Monthly quality assessments indicated that about 6% of coils arrived with edge indentations or scratches to the coating, frequently attributed to steel strap abrasions or rust transfer. Furthermore, three minor hand injuries from sharp steel strap were reported over the course of a year, and costs for disposing of steel scrap continued to rise.

The quality assurance and health & safety teams sought a safer alternative that would maintain the security of the coils while removing the risk of corrosion associated with steel strapping on coated products.

The Solution

Following evaluation of several options, the facility opted for the ITI 71 Battery Strapping Tool in combination with 32–40 mm composite strap across all coated coil production lines. The ITI 71 delivers a maximum 11,000 N strap tension, equalling the holding strength of the previous steel strap, while the broad textile/composite strap offers superior protection for delicate edges.

The ITI 71 is typically operated at around 60% of its maximum tension to achieve an optimal balance between load security and strap stretch. Operators benefit from the integrated cutting mechanism, which allows tensioning and cutting in a single action, removing the need for separate cutters and metal seals. Each tool is supplied with two 18V Li-Ion batteries (providing approximately 400 cycles per charge), ensuring uninterrupted operation throughout a shift, with rapid 40-minute charging times.

ROI Calculation

Prior to implementation – Steel strap & manual equipment:

• Daily output: 160 coils × 4 straps = 640 straps per day
• Average time for strapping: 9 minutes per coil → 160 × 9 = 1,440 minutes per day (24 hours of labour)
• Quality-related losses: 6% of 160 = 10 coils per month subject to claims, with an average loss of €350 per coil → €3,500 per month
• Steel strap, seals, and scrap management (additional compared to textile): approximately €0.30 per coil → €1,050 per year (a modest but tangible cost)

After implementation – ITI 71 with composite strap:

• Revised strapping time: about 5 minutes per coil → 160 × 5 = 800 minutes per day (13.3 hours)
  Labour reduction: 24 h − 13.3 h ≈ 10.7 hours per day → at €18/h ≈ €190 per day or roughly €3,800 per month
• Damage rate reduced to 2% of coils: 3–4 coils per month × €350 ≈ €1,050 per month
  Improvement compared to previous: €3,500 − €1,050 = €2,450 per month saved
• Total monthly savings (labour + quality + materials): approximately €6,300 per month

Investment:
2 × ITI 71 tools (each supplied with 2 batteries & charger): €2,439 × 2 = €4,878
Simple payback: €4,878 ÷ €6,300 ≈ less than 1 month
Even allowing for higher composite strap costs and other contingencies, the site conservatively estimated a return on investment of under 5 months across both lines.

Results

By replacing steel strap with wide composite strap and the ITI 71, strapping time per coil was nearly halved, and incidents of surface damage and corrosion complaints were greatly reduced. Operators now experience easier and safer handling with less fatigue, while quality and health & safety objectives have been achieved without compromising the security of the loads.

“The ITI 71 enabled us to discontinue the use of steel strap on coated coils without sacrificing security. We have seen a reduction in claims, quicker packing, and our team much prefers working with textile strap rather than sharp steel.” — Markus Huber, Packaging Manager, StahlCoil GmbH / Linz, Austria