How banding tools work and their main functions

Banding tools, also known as strapping tools, tension the strap around your load, seal the ends and cut the strap from the coil. They can be powered by hand, battery or compressed air. Each tool is made for a particular strap type and width.

The way the joint is made depends on the strap. Battery powered strapping tool models weld PET and PP strap by friction, while the pneumatic AIR19 welds PET strap. The manual PPST-13/16 uses a metal seal for PP strap. Steel strapping is joined with a seal, clip or a sealless tool. Textile and composite strapping use a wire buckle. You will find the strap itself in the strapping bands section.

Not every tool performs all three actions: for example, a tensioner such as the ITI 71 tensions and cuts textile and composite strapping, and a wire buckle secures the joint.

The type of drive determines where and how the tool can be used. Manual banding tools do not need any power, making them ideal for sites without electricity or compressed air. Battery powered strapping tool models work without hoses or cables, so you can move freely around your warehouse or production area. Pneumatic banding tools require a compressed-air line at the workstation, making them suitable for packing areas already equipped with one.

Before using the tool, pull the strap around the load as tightly as possible by hand. This reduces the time needed to tension the strap and, for battery tools, saves battery charge.

After each strap is applied, inspect the joint. A friction weld should cover the full width of the strap, a metal seal must be firmly crimped, and a sealless steel joint should be properly hooked and cleanly sheared. If the joint is not correct, cut off the strap and repeat the process. Oil, grease or moisture on the strap can prevent a friction weld from holding, so keep the strap clean and dry.

Battery powered strapping tool models and their applications

Battery powered strapping tools operate without hoses or cables. For PET and PP strapping from 9 to 19 mm, models include NEO2, NEO Plus, GT ONE, SIAT VIPER and Signode BXT3; the TES EXTREME is for PET strap 19–25 mm. The ITI 71 is a battery tensioner for textile and composite strapping 16–40 mm.

For steel strapping, the AKU-STEEL DUO and ELECTRA M SERIES are battery powered sets for 19, 25 or 32 mm. These tools tension, seal and cut the strap. Some models are supplied with one or two batteries and a charger.

By strap width, the NEO2 is suitable for 9–16 mm, the SIAT VIPER for 9, 12 or 16 mm, and the GT ONE for 10–16 mm. The NEO Plus is for 16–19 mm, and the Signode BXT3 is available in three versions for 9–19 mm. The TES EXTREME is designed for PET strap 19–25 mm.

These battery powered strapping tool models join the strap by friction welding, so you do not need to purchase metal seals for each joint. The only ongoing cost is the strap itself. Some models, such as the NEO Plus and TES EXTREME, include two batteries and a charger, allowing one battery to charge while the other is in use.

The ITI 71 tensions textile and composite strapping up to 11 000 N; the joint is made with a wire buckle that must match the strap width. Some tools, like the GT ONE, have a soft mode with 500 N tension for lighter or more delicate packs.

A friction weld does not retain the full strength of the strap. On the NEO2, the joint holds about 75 percent of the strap’s strength. The SIAT VIPER achieves between 75 and 85 percent. Therefore, the strength of the strap around the load is limited by the joint.

On the NEO Plus, tension is set on the display in seven gears, not as a force: gear 1 is approximately 600 N and gear 7 about 4 000 N. Record which gear is suitable for each type of pack and use it consistently.

Banding tool subcategories and their contents

To use the table, first locate your strap material and width in the Strap column. Then refer to the subcategory in the first column of that row. Open the subcategory to view all suitable products. The Examples column lists a few typical products for each subcategory, but not every model is shown. For example, PET strap 16 mm wide appears in the rows for battery powered strapping tools and pneumatic banding tools.

Manual and pneumatic banding tools for all strap types

Manual strapping tools include the PPST-13/16 for PP strap with metal seals, the A3, BO-51 and A4, each a sealless steel banding tool, and a manual tensioner for textile and composite strap in three sizes. The B190 pallet threading tool pushes the strap under the pallet with a 1900 mm flexible rod, so no one needs to kneel at every pallet.

Pneumatic banding tools include the AIR19 for PET and PP strap 13–19 mm, the AIR Metal for steel strap 19–32 mm, and the AIR DUO32 for steel strap 19, 25 or 32 mm. All pneumatic tools require a compressed-air supply.

Manual tools do not need a battery or compressed air, making them suitable for places without power or where only a few straps are applied each day.

The AIR19 joins PET and PP strap with a friction weld, so no seals are required. The AIR Metal joins steel strap with a steel clip. The AIR DUO32, a tensioner and sealer, joins steel strap with a seal.

No manual tool in this category is made for PET strap. The PPST-13/16 is for PP strap only, so if you need to strap PET, use a battery powered strapping tool such as the NEO2 or the pneumatic AIR19.

On the A3, the upper strap of a sealless joint should be hooked 1 to 1.5 mm, and no more than 2 mm, into the lower strap. Pneumatic tools require a filter, regulator and lubricator in the air line. The AIR DUO32 set is made for one strap width only, so if you use two widths, you need a separate set for each.

Pallet strapping kits, banding carts and seals

Pallet strapping kits combine a tool, strap and a banding cart in one order. Banding carts dispense PET, PP, cord, textile or steel strap coils, matching the core size and strap type. Banding clips include metal seals for PP strap, clips for steel strap and wire buckles for textile and composite strap.

The kits include a battery, manual or pneumatic tool with strap and a cart.

Battery kits such as the NEO2 kit include the battery and charger. Kits with the PPST-13/16 add PP strap and metal seals, while the CORD kit is for composite strap and includes a manual tensioner, two coils of composite strap, wire buckles and a dispenser cart. The AIR19 kit adds PET strap 15.5 mm and a banding cart; the tool still requires a compressed-air line.

Banding carts are designed to hold the strap coil and allow the strap to be dispensed smoothly without tangling. The cart must fit the coil’s core size: 405/406 mm for PET and PP coils, 200 mm for cord and PP coils (HC2), 76 mm for textile strap, and the HS5 for steel strap coils. Using the correct cart prevents the coil from unwinding on its own and keeps the strap organised during use.

Banding clips must match the strap width and type. Metal seals are available in 13 mm or 16 mm for PP strap, steel strap clips are 16 x 40 mm for manual strapping, and pneumatic clips come in 16 x 40, 19 x 57, 25 x 57 and 32 x 57 mm sizes for pneumatic steel strapping. Wire buckles are used for textile and composite strap and must match the strap width. Each joint requires one seal, clip or buckle, so you should order enough for the number of straps you plan to apply.

Hand, battery or air: which drive is suitable

Banding tools use three drives: hand, battery or compressed air. Manual strapping tools are suitable for a few straps a day and places without power or air. Battery powered strapping tools, such as NEO2 or GT ONE, work at the load and stop at the set tension. Pneumatic models like AIR19 require a compressed-air line but no charging. When the number of straps per day is too high for hand tools, an automatic banding machine straps each pack by itself; these are in the strapping machines category.

If you only need to apply a few straps a day or work in a location without power or compressed air, a manual tool is the practical choice.

When you need to strap many pallets or bundles each day and the work takes place at different locations, a battery powered strapping tool is more suitable. Battery powered strapping tools like the NEO2 or GT ONE are portable and operate without a hose or cable. They go directly to the load, and you can set the tension so the tool stops automatically when the set value is reached.

If your packing line already has a compressed-air line installed, pneumatic tools are a good option. Pneumatic models such as the AIR19 or AIR Metal do not require batteries, so there is no downtime for charging.

A tool goes to the load; a strapping machine requires the load to be brought to it.

For PP strap, the manual PPST-13/16 crimps a metal seal on every strap, so each pack requires seals and lever work. As the number of straps per day increases, this extra step and the cost of seals add up. A battery powered strapping tool such as the NEO2 welds PP strap without seals.

Steel strap can be applied with all three drives. The manual A3 is made for 13, 16 or 19 mm steel strap and the A4 for strap 0.55 to 0.75 mm thick, both joining without seals. The battery AKU-STEEL DUO is for thicker steel strap, 0.8 to 1.2 mm, and the pneumatic AIR Metal and AIR DUO32 require a compressed-air line. The A3 and A4 are lever tools that need both hands on the tool.

For textile and composite strap, the manual tensioner comes in three sizes up to 50 mm for occasional use. The ITI 71 battery tensioner, for 16 to 40 mm, suits many straps a day. Upkeep depends on the drive: manual tools are cleaned and oiled, battery tools need charging and dry, frost-free battery storage, and pneumatic tools require the air line filter to be drained daily and the lubricator filled. Pneumatic tools need enough air volume as well as pressure.

Matching banding tools, strap and cart

Before ordering, check the load, strap material and width. Banding tools must match the strap: PET, PP, steel, textile or composite.

Seals, clips and buckles must fit the strap width. Each joint takes one. The dispenser cart must fit the coil core.

Begin by identifying the strap you use: its material, width and thickness. The tool must be designed for that strap type and size. For instance, if you use 16 mm wide PET strap, you need a tool that covers 16 mm PET, such as the NEO Plus. For steel strap, check that the tool is made for steel strap and matches the width, such as the AKU-STEEL DUO for 19, 25 or 32 mm steel strap.

Next, select the joint type that fits your process. Battery powered strapping tools for PET and PP strap and the pneumatic AIR19 for PET strap weld the joint by friction, so you do not need to order seals. The manual PPST-13/16 uses a metal seal, so you must order seals in the correct width. For steel strap, you can choose a tool that uses a seal or clip, or a sealless tool such as the A3, BO-51 or A4. Textile and composite straps are joined with a wire buckle that matches the strap width.

Compare the core size of your coil with the banding cart. Coils of PET and PP on a 405/406 mm core need the PET/PP banding cart. Cord and PP coils on a 200 mm core go on the HC2 cart. Textile strap rolls on a 76 mm core go on the textile strap cart, and steel strap coils go on the HS5 cart.

Work out the number of straps you apply daily and check whether the strapping point has mains power or compressed air.

Match the PET strap to the battery powered strapping tool by both width and thickness. For example, 15.5 x 0.9 mm PET strap fits the NEO2 and GT ONE, 19 x 1.0 mm fits the NEO Plus, and 25 x 1.2 mm fits the TES EXTREME.

Clips must be compatible with both the banding tool and the strapping band. Pneumatic clips are not suitable for manual tools, and the 16 x 40 mm clips for manual strapping are used with a manual tensioner and sealer. Always check the strap width matches the banding cart. The PET/PP banding cart is designed for strapping bands 10–19 mm wide on a 405/406 mm core. The PP strapping bands from this shop are supplied on a 406 mm core, so they fit this cart. Both the PET/PP banding cart and the HC2 model feature a brake to stop the coil from unravelling when the band is pulled, and include a box or tray for banding clips and the tool.

Factors influencing the price of banding tools

The price of a banding tool is determined by the drive type (manual, battery powered or pneumatic), the width and tension of the strap, and whether the tool is supplied with one or two batteries. For metal strapping, some sets include both a tensioner and a sealer. Ongoing costs come from the strapping bands, banding clips, seals and buckles. Each product card displays the price.

The main ongoing expense is the strapping band itself. For tools that require a seal, clip or buckle, you will need one for each joint, which increases the cost over time. Each product card provides a Get offer button to request a quotation and an Add to inquiry button to gather several products into a single request.

To calculate the cost per strap, measure the length of band needed to go around the pack plus the overlap, then divide the coil length (shown on the strapping band page) by this figure. For example, a 19 x 1.0 mm PET coil contains 1,000 metres. This gives you the number of straps per coil and, as you need one per joint, the number of seals, clips or buckles required.

Seals, clips and buckles are supplied in boxes. For example, PP seals are packed in boxes of 1,000 and pneumatic clips in boxes of 1,000 (800 for 32 x 57 mm). Wear parts are also part of the running cost. On battery powered strapping tools for plastic bands, the cutter, toothed plates and tension wheel are wear parts. For the AKU-STEEL DUO, the moving jaw and feed wheel are considered wear parts.

Safe use of banding tools

When operating banding tools, always wear gloves and eye protection. Stand to the side of the band while tensioning. A tensioned band can recoil when cut, so always cut it from the side using banding cutters. Edge protectors help prevent damage to the band on sharp corners.

Never lift or move a load by its band. Keep the coil in a banding cart to prevent it from unwinding by itself.

The edges of metal strapping are sharp and can cause injury if handled without protection. Eye protection is essential, as the band can spring back when cut.

Always stand to the side of the band while tensioning, not directly in line with it. This reduces the risk of injury if the band breaks or slips during tensioning.

Cutting from the side keeps your body out of the path of the band if it recoils.

Use edge protectors on sharp corners to stop the band from being damaged or cut by the load.

When cutting a tensioned metal band, always hold the upper section, as the lower band will snap forward. Keep your fingers away from the tension wheel area and never place your hand between the band and the pack during tensioning. Never send a load with a joint that is not properly formed.

Consider hearing protection where necessary. The SIAT VIPER produces around 96 dB(A) during welding, and the AIR19 manual recommends earmuffs if noise exceeds 85 dB(A). If a band jams in a battery powered strapping tool, remove the battery before cutting the band free. When cleaning a tool with compressed air, always wear eye protection, as dust may be blown towards your face.

Frequently asked questions about banding tools

Which banding tool should I use for metal strapping?

For metal strapping, use the AKU-STEEL DUO or ELECTRA M SERIES battery powered sets for 19, 25 or 32 mm bands, or the manual sealless A3, BO-51 or A4 models. Pneumatic banding tools AIR Metal and AIR DUO32 are also available for metal strapping.

Do battery powered strapping tools require seals?

Battery powered strapping tools for PET and PP bands weld the band by friction and do not require metal seals. For metal strapping, both battery powered sets require seals: the AKU-STEEL DUO uses a steel seal, while the ELECTRA M SERIES forms a double-notch seal joint. The ITI 71 for textile and composite bands requires wire buckles.

What is included in a pallet strapping kit?

A pallet strapping kit includes a banding tool, strapping band and a banding cart. Some kits also provide a battery and charger, metal seals or wire buckles, depending on the tool and band supplied.

Which banding cart is suitable for which coil?

The PET/PP banding cart is suitable for PET and PP coils on a 405/406 mm core. The HC2 cart is designed for cord and PP coils on a 200 mm core. The textile band cart fits textile rolls on a 76 mm core. The HS5 is for metal strapping coils.