Frequently Asked Questions
Strap Selection and Specifications
How do I select the right strap for my application?
Understanding the product’s shape, material, and weight is the starting point for choosing the right strapping solution. From there, consider the following factors:
- Load type: Is the load rigid, compressible, or expanding? Rigid loads like steel or lumber call for high-strength strapping such as polyester or steel. Compressible or expanding loads like boxes, cartons, or bundled paper are well-suited to polypropylene.
- Break strength required: Match the strap’s break strength to the weight and movement demands of your load.
- Application method: Will you be applying the strap by hand, with a battery-powered tool, or with an automatic machine? Each has different compatible strap grades.
- Environment: Will the load be exposed to heat, moisture, or outdoor conditions?
If you are unsure where to start, contact our team. Our experts can help you find a tailored solution for your specific application.
Plastic & Steel Strapping Application Guide
| STRAP TYPE | APPLIED BY | CLOSURE USED | LOAD CHARACTERISTICS | TYPICAL APPLICATIONS |
|---|---|---|---|---|
| POLYPROPYLENE STRAPPING | ||||
| Standard Hand Grade | Hand Manual Tools Power Tools |
Buckles Buckles/Seals Friction Weld |
Compressible Expandable |
Palletizing Lightweight Package Reinforcement |
| Low Elongation | Manual Tools Semi Auto/Arch Machines |
Seal Friction Weld Heat Welds |
Rigid Expanding |
As a Substitute for Steel or Polyester |
| Semi Automatic Machine Grade |
Semi Automatic Machines |
Heat Seal | Compressible Expanding |
Bundling Carton Closing Carton Reinforcement UPS Unitizing |
| Machine Grade | Automatic Machines |
Heat Seal Friction Weld |
Compressible Expandable |
Similar to Semi-Automatic with Higher Volumes |
| POLYESTER STRAPPING | ||||
| Hand Grade | Manual Tools Power Tools |
Seals Friction Weld |
Rigid | Heavy Duty Palletizing As a Substitute for Steel |
| Machine Grade | Automatic Machines Fully Automatic Strapping Systems |
Friction Weld Heat Welds |
Rigid | Fine Paper Beverage Cans/Bottles Bricks/Blocks Lumber/Timber |
| CORD STRAPPING | ||||
| Polyester Cord | Hand Manual Tools |
Tied/Buckles Buckle/Seals |
Combination | Agricultural Building Trades Boat Industry |
| Rayon Cord | Hand Manual Tools |
Tied/Buckles Buckle/Seals |
Tying Applications |
|
| STEEL STRAPPING | ||||
| Manually Applied Steel* |
Manual Tools Power Tools |
Seals Sealless Joints |
Rigid | Steel Services Centers Heated Product Product with Sharp Edges |
What is break strength, and how does it relate to choosing the right strap?
Break strength is the amount of force required to cause the strap to fail under tension, typically expressed in pounds or kilograms. It is one of the primary specifications to evaluate when selecting a strapping material.
When selecting strap, the break strength of the material should exceed the forces the strap will experience during handling, shipping, and transit. Heavier or higher-value loads, or loads subject to significant movement, generally require higher break strength.
PAC’s polyester strapping offers break strengths up to and beyond what many steel applications require, while also maintaining tension if the load shifts or settles.
Keep in mind that effective break strength at the joint is also influenced by joint efficiency.
What is elongation, and why does it matter for load securement?
Elongation refers to how much a strap stretches under tension. Different strapping materials have very different elongation characteristics, and understanding this helps you choose the right strap for your load.
- Polypropylene has higher elongation, which makes it well-suited to compressible or expanding loads where some give is acceptable. It accommodates movement and settling during storage or transit while maintaining package integrity.
- Polyester stretches under initial tension, but most of that elongation is recovered after application. The result is a strap that maintains high retained tension even if the load shrinks or settles during transit, staying tighter than both steel and polypropylene over time.
- Steel has very low elongation and is typically used on rigid loads that will not compress or shift.
For loads that must stay tightly contained across a long transit, retained tension after elongation recovery is a critical performance factor.
How does temperature affect strapping performance?
Temperature can impact both the tensile strength and the retained tension of plastic strapping materials. Polypropylene is generally suited to standard indoor and ambient shipping environments, but can become brittle in extreme cold or soften in high heat. Polyester strapping maintains its performance across a broader temperature range and is better suited to applications involving heat exposure during transit or storage.
Steel strapping is the most temperature-resistant option and is the preferred choice for applications involving heated products or environments with extreme temperature fluctuations. If your application involves exposure to high temperatures, sharp edges, or product that is hot at the time of strapping, steel may be the appropriate material. Contact our team to discuss the specific conditions of your application.
What is the difference between embossed and smooth strapping?
Embossed strapping has a textured surface pattern pressed into the material during manufacturing. The texture improves grip on the load and can help hold friction welds more effectively. It is common in hand-grade polyester strapping applications.
Smooth strapping has a flat surface and is typically used in machine-grade applications where consistent feeding through the strapping machine is important. The smooth surface reduces friction within the machine’s feed track, which helps with reliable performance at high cycle speeds.
When selecting between embossed and smooth, your application method and equipment type are the primary factors to consider.
Material Comparisons
What is the difference between polyester cord strapping and steel strapping?
Polyester cord strapping and steel strapping are both high-strength options used for demanding applications, but they differ significantly in how they perform and how they are handled.
Steel strapping is a rigid metal band that provides very high break strength and low elongation. It is the recommended choice for heavy loads with sharp edges, heated products, or applications at steel service centers. However, steel is heavy, difficult to handle, and poses safety risks. The sharp edges can cause cuts, and when cut under tension, steel has a “spring back” that can cause serious injury. Steel is also less environmentally friendly and not as easily recycled.
Polyester cord strapping is made from woven polyester fibers, which give it a combination of flexibility and strength. It is hand-applied with manual tools and sealed with buckles or tied, making it a portable, easy-to-use option. It is commonly used in agricultural applications, building trades, and the boat industry. While it offers meaningful break strength, it differs from high-performance flat polyester strapping and is not applied with battery-powered tools or automatic machines.
What is the difference between polyester strapping and polypropylene strapping?
Polyester (PET) and polypropylene (PP) are both plastic strapping materials, but they are suited to different applications.
Polypropylene strapping is the most economical plastic strapping option. It is lightweight, flexible, and well-suited to light- and medium-duty applications such as bundling, carton closing, and unitizing. It has higher elongation and accommodates compressible or expanding loads. It is available in both hand-grade and machine-grade configurations and is compatible with manual tools, semi-automatic machines, and automatic strapping machines.
High-performance polyester strapping is used for heavy-duty applications where higher break strength and retained tension are required. Polyester stretches under initial tension but recovers most of that elongation, keeping the strap tight even if the load shrinks or settles during transit. It maintains higher retained tension over time compared to polypropylene and steel and is commonly used as a substitute for steel strapping in heavy-duty palletizing, building materials, and other demanding applications. High-performance polyester hand-grade strap is applied with manual or battery-powered tools, but is not compatible with semi-automatic or automatic strapping machines.
If your operation uses a semi-automatic or automatic machine and requires a heavy-duty strap, polypropylene strapping is the compatible option.
What are alternatives to steel strapping?
High-performance polyester strapping is the most widely used alternative to steel strapping. It combines the strength of steel with the safety and economy of plastic, resulting in a more secure load at a lower cost with meaningfully improved safety for operators.
Other alternatives include polypropylene strapping for lighter-duty applications and polyester cord strapping for applications in agriculture, building trades, or the boat industry.
The shift away from steel is driven by safety, cost, and environmental considerations. Steel is heavy, has sharp edges, and poses a spring-back injury risk when cut under tension. Polyester eliminates those risks, is lighter to handle, and can reduce costs by 25-50% compared to steel strapping. PAC also offers recycling support for polyester strapping, which is made from high recycled content and is itself recyclable at the end of life.
Sealing, Tooling, and Technique
How do I tension and seal strap?
The method for tensioning and sealing strap depends on the material type and tool being used.
With manual tools, the operator uses a tensioner to ratchet the strap tight around the load, then applies a crimped metal seal or buckle to hold the joint. This method works for polypropylene, polyester, cord, and steel strapping.
With battery-powered or pneumatic tools, the tool tensions the strap and creates a friction weld joint by using heat generated through vibration to fuse the two layers of strap together. No separate seal is required. This method applies to polypropylene and polyester strapping.
With automatic and semi-automatic strapping machines, the machine feeds, tensions, and seals the strap in a single cycle, using either a heat seal or friction weld, depending on the machine and strap grade.
All plastic strapping can be applied manually and sealed with buckles or seals. A moderate investment in powered tooling can frequently be cost-justified by the savings on seals and buckles over time.
What is joint efficiency?
Joint efficiency is a measure of how strong the sealed joint is relative to the total break strength of the strap, expressed as a percentage. A strap with a 1,000 lb. break strength and 80% joint efficiency would have a joint that holds up to approximately 800 lbs. before failing.
Joint efficiency varies by sealing method. Manual tools with crimp seals typically achieve around 60% joint efficiency. Battery-powered tools that create a friction weld increase joint efficiency to approximately 85%, because the weld bonds the strap material itself rather than relying on a mechanical fastener. Machine-grade applications using heat or friction welds achieve similar results.
Higher joint efficiency means the strapping can handle more force without failing at the joint, which directly reduces the risk of product damage during transit.
Can I use the same tools with polyester as with steel?
No. Plastic strapping tools and steel strapping tools are not interchangeable. Steel strapping requires its own set of tensioners, sealers, and cutters, which are built to handle the rigidity and weight of steel banding. These tools will not work with plastic strapping.
Polyester and polypropylene strap use plastic-specific tools, including manual tensioners and sealers, battery-powered combination tools, and pneumatic tools. If you are transitioning from steel to polyester strapping, you will need to invest in new tooling. PAC offers a full line of plastic strapping tools and can recommend the right equipment for your application.
What is the difference between manual, battery-powered, and pneumatic strapping tools?
- Manual tools require the operator to physically ratchet tension into the strap and apply a separate crimp seal. They are portable, require no power source, and are a practical option for low-volume or intermittent applications. However, tension applied is dependent on the operator’s strength and technique, which can lead to inconsistent results. Manual tools typically achieve around 60% joint efficiency.
- Battery-powered tools tension and seal the strap in a single operation, creating a friction weld without a separate seal. They deliver consistent tension regardless of operator strength or experience, improve joint efficiency to approximately 85%, and significantly reduce the risk of repetitive strain injuries. They are well-suited to medium and high-volume operations where consistency and speed matter.
- Pneumatic tools offer similar performance to battery-powered tools but require a compressed air source. They are commonly used in fixed workstations or production lines where an air supply is readily available.
The right choice depends on your application volume, portability needs, and facility setup. PAC’s team can help assess your operation and recommend the appropriate tooling.
Load and Application
I already wrap my pallets. Why do I need to strap them?
Wrapping and strapping serve different purposes and work best together. Stretch wrap holds items on the pallet as a unit and provides surface protection, but it does not provide the vertical compression or high-tension containment needed to keep heavy or rigid loads secure during transit.
Strapping applies direct, measurable tension around the load and pallet, preventing shifting, tipping, or compression failures that stretch wrap alone cannot address. For heavy pallets, unitized bundles, or loads that must withstand the forces of stacking and transit, strapping provides a level of load security that film wrapping cannot replicate.
Many operations use both: wrap for surface cohesion and moisture protection, strap for structural containment and tension.
Machines and Automation
How do I choose the right strapping machine?
The right machine depends on your strapping volume, your packaging line setup, and the type and size of product you are securing. Key considerations include:
- Volume: Low-to-medium volume operations are typically served well by a semi-automatic machine, where the operator places the strap around the load and the machine tensions and seals it. High-volume operations benefit from a fully automatic machine that handles the full strapping cycle with minimal operator involvement.
- Package size and strap width: Confirm that the machine’s arch size accommodates your package dimensions, and that the machine is compatible with the strap width you intend to use. Automatic machines are configured for a specific strap width at the time of purchase and cannot simply switch widths by swapping rolls.
- Integration: If you need the strapper to function as part of a conveyor or pallet wrapping line, PAC offers integrated strapping systems designed to fit that workflow.
Contact our team for a recommendation based on your specific operation.
Can I automate the strapping function?
Yes. PAC offers a range of automatic strapping machines and fully integrated pallet strapping systems designed to automate the tensioning and sealing process. Automatic machines complete the full strapping cycle without operator intervention beyond positioning the load, and can be integrated into conveying and wrapping lines for a continuous production flow.
PAC also offers pallet strapping systems, including the PSS733 heavy-duty series and the Pallet PAC Plus 602 light-duty series, which manage the full strapping process within an integrated line using polyester or polypropylene strapping.
What is the difference between a semi-automatic and a fully automatic strapping machine?
With a semi-automatic strapping machine, the operator manually positions the strap around the load and feeds it into the machine. The machine then tensions and seals the strap automatically. This type of machine is well-suited to operations with moderate volume or varying package sizes.
A fully automatic strapping machine handles the entire process, including feeding the strap around the load, tensioning, and sealing, without requiring the operator to manually thread the strap. These machines are designed for high-volume, consistent-output production lines where speed and throughput are the priority.
Both machine types are available in various arch sizes to accommodate different package dimensions, and both can be integrated into conveyor systems.
How fast can a strapping machine run?
Machine speed varies by model. As a reference point, the SM65 automatic strapping machine delivers speeds of up to 65 straps per minute, making it one of the fastest machines in its class. Other models in the PAC lineup operate at varying cycle speeds depending on the application and machine design.
For semi-automatic machines, cycle speed is also influenced by operator pace. Contact our team to discuss the throughput requirements of your specific operation, and we will identify the right machine.
Product Details and Storage
What core sizes and coil dimensions are available?
PAC strapping is available in a variety of core and coil configurations to suit different dispensing equipment and machine requirements. Common configurations include 16×6 coils, 8×8 coils, and 9×8 coils, depending on the product type. Specific dimensions and configurations are listed in the product specifications on each product page and in the PAC product catalog.
If you are purchasing replacement strapping for an existing machine, confirm that the core size matches your machine’s coil holder specifications before ordering.
How should I dispose of used strap?
PAC High Performance Polyester strapping is made from high recycled content and is itself recyclable at end of life. PAC offers solutions for customers and municipalities to support strapping recycling and help close the loop on material use.
For polypropylene strapping, recycling availability may vary by location and local recycling infrastructure. Steel strapping can typically be recycled as scrap metal.
Contact our team for guidance on recycling options available in your area.
Explore Our Resources
We proudly offer a full line of plastic and steel strapping products for a range of industries. Here at PAC Strapping Products, we’re dedicated to helping our customers learn more about how our strapping equipment functions. Watch our video presentations, view our PDFs with more information on our products and tools, read our Catalog, get some of your questions answered on our FAQ page and more!