Use-Case – NEO2 Battery Strapping Tool

320 minutes reduced to 160 minutes
Daily labor saving €66.67 achieved
Machine runs at 60% capacity
Rework cut from 2 to 0.5 pallets
ROI reached in around 25 days

Metric	Previously (Manual / Semi-automatic)	Subsequently
Pallets/day	80	80
Strapping time/day	320	160
Labor cost/day - €	133.33	66.67
4 straps per pallet x number of pallets	320	320

A medium-scale logistics warehouse processes 80 pallets per day.
Each pallet is fastened with 4 plastic straps.

Prior to automation, strapping was carried out manually using a PPST-13 mechanical strapping tool.

Manual strapping cycle time per pallet: 4 minutes
Total time spent strapping each day: 80 × 4 = 320 minutes (5.33 hours per day)
Labour cost: €25 per hour
Daily labour expense for strapping:
5.33 h × €25 = €133.33 per day
Rework required due to insufficient strap tension or sealing: 2 pallets per day
Seals are required for each strap

Manual strapping occupied more than half of the operator’s shift and led to significant fatigue.

After Installing NEO2 Battery Strapping Tool

(Machine is operating at only 60% of its maximum capacity)

With the NEO2 battery-powered strapping tool, which provides both tensioning and friction welding, strapping times were reduced:

Strapping cycle per pallet: 2 minutes
Total daily strapping time: 80 × 2 = 160 minutes (2.67 hours per day)

Labour cost for strapping:
2.67 h × €25 = €66.67 per day

Strapping quality became more reliable:
Rework reduced to 0.5 pallet per day

Operators experienced less fatigue, productivity improved, and the remaining time could be used for staging, picking, and documentation.

Before / After Table

Metric	Before (Manual PPST-13)	After (NEO2 Battery Tool)
Pallets/day	80	80
Strapping time/day	320 min	160 min
Labour cost/day	~€133.33	~€66.67
Rework pallets/day	2	0.5
4 straps per pallet*nr of pallets	320	320

ROI Calculation

Machine cost: 1,199€

Daily savings:
€133.33 – €66.67 = €66.67 per day

Monthly savings (22 working days):
€66.67 × 22 = €1,466.74 per month

Payback period:
€1,199 ÷ €1,466.74 ≈ 0.82 months
≈ 25 days

This means the investment is recouped in roughly four working weeks.

Conclusion

The warehouse halved its strapping time, minimised rework, reduced operator fatigue, and achieved greater operational flexibility.
The equipment paid for itself in less than a month.

Testimonial

“Using the battery strapping tool, I can complete all the strapping in less than three hours, whereas it used to take up the majority of my shift. The seals are more secure now, and we no longer need to re-strap pallets.”
— Martin K., Warehouse Operator, Slovenia