7 Ways Automatic Strapping Improves Packaging Efficiency

There are many situations where strapping — and specifically automatic strapping — is superior to alternative end-of-line packaging options. Fresh produce is a great example of a major industry ($96 billion market size in 2023) where packers can benefit by upgrading common options like semi-automatic strapping and turntable wrapping setups to an automatic strapping solution.

There are several automated strapping advantages that can give fresh produce packaging companies a cutting edge in the years ahead.

The most obvious advantage is that an automated strapping machine dramatically increases output. By removing the human element and setting up streamlined solutions that run themselves, fresh produce packers can boost throughput. This is a serious consideration in a market that is set to handle 59 billion units of goods per year by 2028.

Machines like the Reisopack 2915 are engineered to significantly boost throughput by reducing downtime between loads. Along with the natural efficiencies of automation, the 2915 model features lateral mobility, allowing it to move between up to four strapping stations at a time and package up to 60 pallets per hour. 

This kind of efficiency is ideal for produce packaging facilities with limited space for conveyors to maximize uptime.

Sectors like fresh produce are grappling with chronic labor shortages at the moment. This takes packaging automation from an efficient alternative to an important source of workforce relief. Automating mundane, repetitive tasks, such as strapping packages and pallets, frees up personnel to focus on more complex and critical tasks.

This is particularly important as the cost of labor rises. Signs indicate that it is becoming more difficult to source labor for this key area of the economy. At the same time, labor already eats up between 29% and 38% of production costs for fruit, tree nut, vegetable, and similar agriculture operations. 

In situations like this, even replacing a turntable wrapping setup with something like the semi-automated Reisopack 2830 can help. The counterweighted sealing head, vertical reach, and fixed battery accelerate the process and remove physical strain on workers. Full automation removes the need for human intervention.

Automation has a subtle but important impact on other areas besides labor costs and throughput. For example, manual strapping is often performed with inexpensive, low-grade polypropylene and buckles. This results in uneven tension, poor placement, and risk of load shifting, causing product damage during transport. Unsecured loads are also a safety hazard when moving pallets into and out of transport vehicles. 

Another concern is hand-strapping taller loads (which are common in the fresh produce industry). Manual application can lead to uneven tension from top to bottom as human workers reach up and attempt to apply even pressure.

Automated machines like those in the Reisopack line use machine-grade polyester (PET) straps and electronic tension control. This ensures uniform strapping from floor to ceiling. Each layer is even and does not elongate in warm weather. 

The result is:

• Greater predictability

• More stable loads

• Reduced transit damage

Fresh product packaging is forecast to increase 2.4% annually for the next few years, which means the pressure on packaging facilities is only going to increase moving forward. Automation can improve packaging efficiency in end-of-line strapping by optimizing strap placement and tension. 

Along with the quality of the straps themselves, Reisopack machines avoid overusing material — a common issue with manual processes. Automated strapping is cleaner, tighter, and reduces consumable costs. It is more affordable than the breathable netted film often used in produce packaging, as well.

Sustainability is also a factor here. As overall throughput increases, it is important to avoid unnecessary waste. Reducing the overall quantity of strapping helps with this. In addition, sustainable strapping materials, like EAM-Mosca’s recyclable PET strap, reduce environmental impact.

Automated strapping options are naturally less likely to lead to mistakes. The potential for human error is eliminated, and current technology can even detect subtle issues that previously required human intervention.

Good examples of this are electronic tension control and machine-based consistency. Another is corner board alignment. If boards are compromised or misaligned during packaging, it can seriously impact pallet integrity. 

One of the standout features that makes units like the Reisopack 2905 a superior option is that it comes equipped with CRC Technology. This automatically detects and corrects cornerboard alignment, preventing misplacements that could compromise an entire load. This improves reliability and avoids unnecessary errors in packaging and shipping.

In a world like fresh produce packaging, margins are tight, labor is high, and a single damaged shipment can destroy profit margins. This makes load stability a priority.

Traditional solutions, like wrapping turntables, can compromise stability through uneven application. Many fresh produce packaging facilities also pre-slit their film to improve airflow, but this naturally compromises pallet integrity.

This can lead to unplanned expenses due to product damage if a poorly wrapped load tips. Again, automation here can be a game-changer. Things like cornerboard integration and strap precision allow Reisopack machines to keep products tight, upright, and protected, from initial loading to long-haul routes and final delivery.

Finally, automated strapping is good for the people on the floor. Ergonomically speaking, manual strapping often involves lifting heavy tools, especially for tall pallets, which require lots of overhead application. Stretching to reach tall pallets creates real injury risks and ongoing fatigue. 

This work is so gruelling that our team has seen some fresh produce packers have to replace their strapping workers every couple of months because no one wanted the job. This changes with the precision and automation of higher-quality strapping products.

Both Reisopack's semi-automatic and automatic systems drastically reduce physical strain. Features like counterweights and adjustable strap heads eliminate repetitive motions and enable more ergonomic workflows.

Passing human repetitive labor off to machines also naturally reduces the danger of injury, improves risk prevention, and creates safer workspaces.

Strapping may not be a traditional priority for fresh fruit packers and similar companies, but it is well worth an assessment. Things like manual application, low-quality strapping, turntables, non-conveyable environments, and high labor costs can turn end-of-line packaging into an inefficient and expensive process.

An investment in quality products and automated solutions, it can transform safety, throughput, and overall operational efficiency. This can widen margins and improve profitability, even in an industry as fast-paced and demanding as fresh produce.

If you’re still relying on manual labor to secure pallets, it’s time to consider an upgrade. Reach out to our team through our chat in the bottom corner for a quick and easy quote. If you have more questions, you can also contact us directly, and a strapping expert will be in touch soon to help you find the right solution for your needs. We look forward to connecting!