In the logistics and packaging business, strapping plays a significant role in securing goods for transport, storage, and handling. Whether it bundles together materials or stabilises loads on a pallet, strapping ensures the contents remain sound and guarded. However, optimum tensioning is required to avoid damage or instability, hence the advent of strapping tensioners.
This guide provides a step-by-step procedure for using steel, plastic, and battery strapping tensioners to get the best results from your load-securing application.
Why Use a Strapping Tensioner?
A strapping tensioner is a tool intended to create a certain amount of force and pull strapping around a load. This makes the load secure so that it does not move about and causes no damage during transport. 
Advantages Of Using Strapping Tensioners
- Load stability is maintained using consistent tension.
- Manual labour is lessened compared to having to use a hand-tightening method.
- Safety is enhanced due to the absence of loose strapping or ineffective strapping methods.
- The efficiency of packaging and transporting operations improves.
- Complies with Australian load restraint regulations.
Types of Strapping Tensioners
Knowing how to use a strapping tensioner will only come after you have understood the types of strapping tensioners:
Steel Strapping Tensioner
Steel strapping tensioners are specifically formed for heavy-duty applications involving industrial payloads, heavy machinery, and construction materials. This tool applies strength to make the steel strap tight and is handled with metal seals or crimping tools to ensure a secure hold.
Best for: Maximum durability and security required heavy-duty loads.
Plastic Strapping Tensioners
A plastic strapping tensioner works with polypropylene (PP). It is often used in light applications, such as carton securing or bundling of smaller products.. Most of the time, these tensioners work with buckles, friction welds, or heat seals for closure.
Best for: Medium to lightweight loads needing flexibility.
Battery-Powered Strapping Tensioners
Battery-powered strapping tensioners represent the latest advancement in strapping technology. These tools use rechargeable lithium-ion batteries to power a motor that automatically applies precise tension to strapping material. They can work with both plastic and steel strapping depending on the model.
Best for: High-volume operations where speed, consistency, and reduced operator fatigue are priorities. These tensioners are ideal for warehouses processing numerous pallets daily.
A Stepwise Procedure for Using a Strapping Tensioner
Step 1: Choosing a Suitable Strapping
The correct selection of strapping and tensioner depends on the weight and nature of the load. Steel strapping tensioners are best for heavy-duty loads, while plastic strapping tensioners are suitable for medium to light duty. Battery-powered tensioners can handle various strapping types based on their specifications. Ensure that the width of the strapping conforms to the specifications set forth for the tensioner, functioning together in harmony toward the required goals.
Step 2: Arranging Strap About the Load
Wrap the strap securely around the package or pallet. The strap must lay flat against the load, with no twists or kinks. The two ends of the strapping would overlap where tension would be placed.
Step 3: Loading Strap into Tensioner
For a steel strapping tensioner, insert the free end of the steel strapping into the tool’s tensioning slot, aligning it directly with any pathways to allow free movement during operation.
For plastic or battery strapping, insert the strap through the tool’s gripping mechanism, keeping it flat without twisting or tangling.
Step 4: Apply Tension
For manual tensioners: Grasp the tensioner handle and pull down hard, tightening the strap. The mechanical action will gradually pull the strap tighter around the load. Do not overtighten, as too much force can damage the packaging and/or harm the integrity of the strap.
For battery-powered tensioners: Set the desired tension level on the device’s control panel, then press the operation button. The tensioner will automatically apply the precise amount of tension needed.
Step 5: Strap Securing
With the tension applied as required, it is time to seal the strap in place:
For steel strapping: Place a metal seal over the overlap and crimp or seal it into place using a crimper or sealer.
For plastic strapping: Secure the strapping using a buckle, heat sealer, or friction weld tool.
For battery-powered tensioners: Many models include an automatic sealing function that heat-welds or crimps the strap once tension is applied. If using a model without this feature, follow the appropriate manual sealing method.
Step 6: Cut Off Excess Strapping
After securing the strap, cut off the excess material with a cutter (usually integrated into the tensioner), being extra vigilant against sharp edges, especially with steel strapping. Battery-powered models often include an automatic cutting function.
Step 7: Inspect the Secured Load
Check that the strapping is tight, appropriately sealed, and positioned correctly. A well-tensioned strap should hold the load tight without feeling loose. Repeat the procedure for a better grip if it feels loose or improperly sealed.
Essential Safety Tips for Using Strapping Tensioners:
- Protective gloves must be worn to prevent cutting off hands due to sharp, strapping edges.
- Ensure proper positioning of the tool because misalignment or slipping may quickly happen.
- Over-tensioning may, however, lead to weakening or breaking of the strap.
- For battery-powered tensioners, ensure proper maintenance of batteries and follow charging procedures.
- Store tools properly to keep them efficient and long-lived.
- Follow Australian load restraint guidelines so that transport operations are safe and sound in compliance with these laws.
Common Mistakes to Avoid
- Wrong Tensioner for Strapping Type – A plastic strapping tensioner will not work correctly on steel strapping, and vice versa.
- Not Enough Tension – Loose strapping makes unstable loads.
- Over-tightening – Too much tension can damage the strap and the load.
- Improper Sealing Technique – Using the wrong seal or not securing the strap correctly can lead to failure during transport.
- Neglecting Battery Maintenance – For battery-powered models, failure to maintain proper battery charge can lead to incomplete operations and downtime.
Conclusion
Using a strapping tensioner correctly is essential for securely handling loads. Steel strapping tensioners are used for industrial applications, plastic strapping tensioners are used for lighter packaging, and battery-powered tensioners offer efficient solutions for high-volume operations. The proper process, therefore, ensures stability, compliance, and safety.
By investing in quality tensioning tools and implementing best practice procedures, businesses can reap operational benefits associated with lower strapping damage risks and improved overall transport security. Proper training and the right equipment are all it takes to transform ways to secure better and reliably restrain loads for those optimising their strapping solutions.
