Manual PP Strapping: How to Get Consistent Results at a Packing Bench

Using the same blue strap on the same type of carton bundle: Two operators. One bundle can be easily moved. The other one comes to dispatch with a crushed corner and a loose loop. The variation can be due to where the operator put the strap, the tightness of the strap or the way the joint was formed. This is information a common work instruction can reveal.

Manual PP strapping is beneficial at fulfillment benches, packing stations in warehouses, and other workplaces where carton sizes and order quantities vary. Supervisors/Operators aim is to make a good pack repeatable. Establish the bench around the job, establish that criteria for a completed bundle and refer to it when another person assumes responsibility.

Select the Package prior to setting up the Bench.

Begin by starting with an order representative. Determine if the strap is to be used to "strengthen" one closed carton or to tie a bundle of cartons together. Ensure the cartons are level and the groupings will be able to hold the smaller ones. When a box is too soft or has an irregular surface for the strap pressure, adjust the pack arrangement before changing to a tighter setting.

Yalan's PP hand strapping products are suitable for carton, parcel and light industrial goods. Its blue PP strapping for Order Fulfillment is engineered for manual packing stations for carton and grouped security. Select the grade in the package and handling. If heavier or more demanding loads are to be stored on the bench then ensure that these are different to the bench loads in packaging instructions so that staff can identify when the bench standard is not applicable.

In the strapping category, Yalan talks about extrusion and embossing equipment. If the approved hand strap is embossed, note the embossed finish, grade and dimensions. The band that is used during the bench trial should be specified in the purchasing description.

Place Strap and Its Closure Together at the Station.

Manual station requires the use of compatible strap, tensioning tool and closure. Manual strapping tools and tensioners are among the variety of strapping tools offered by Yalan. Review instructions for system selected; verify PP strap width, thickness and type of closure. Different buckle systems and a system to crimp a separate seal have different requirements; lay out the parts for the approved system.

Keep the roll on product in an appropriate dispenser. Maintain free end control and locate the roll so operator doesn't have to cross a walking path to draw strap. Keep the right type of closures in front of the students and other similar parts in other areas for other grades. For a pair of related families of packages use the work instructions from the bench to indicate which roll and closure go together.

Display sample of the Strap Path on Finished Carton

Create one reference bundle, using the same carton style and fill as in production. Mark on the photograph or sample where the intended strap position should be so that the next operator will be able to see this. Wrap the strap flat around the load and ensure that it rests on load supported areas. Avoid weak flaps, carton openings and any feature that will catch the band.

If the band will be putting pressure on a weak edge, then use appropriate paper edge protectors. Make sure the protector remains in place when applying and the band rests on the protector. On grouped cartons examine the manner in which the strap crosses the outside boxes and whether it is holding the group of boxes together as intended. A reference picture should depict an entire pack and the contact point which is most difficult to locate.

Discuss and determine what the correct tension will look like.

Read and follow the tool directions and use the tool package approved setting or method. Observe the carton as the strap is tightened. It is important that the finished loop hold the desired group in place, and that the box and contents be left in a satisfactory condition. If bending or distortion at the corners or in the side panels occurs, check the bearing surface and application process before beginning the batch.

If the job is to be continued by a different operator, use the same reference. Request supervisor to audit the initial carton after a change in carton size, fill or closure supplies. Make the check as practical as possible. It should be easy for an operator to compare the bundle with a photo and identify if a strap has moved out of place or if an edge has been pulled into the bundle.

Before releasing the bundle, inspect the Joint to check for any damage.

Review closure following system directions. For a compatible seal system, verify overlap/crimp is as per approved reference. Using a compatible buckle, determine if the strap is routed the correct way and if the ends are in the right position. Avoid placing hands or face in the direction of the load and follow tool manufacturer's recommendations for handling or cutting strap.

If a joint appears to be square on the bench, it might still require validation once handled. Before dispatch reviewing representative packs which will be undergoing movements. If the strap slips or if an edge has been affected, make a note of the location of the change and keep a sample if possible. Take into account Yalan's hand and machine strapping guide when considering if the work will still accommodate a manual station in view of the changing volume or changing package type.

Ensure that the First Pack is part of each shift handover.

Leave approved roll reference and picture of finished package at bench. Note the closure, strap path and any protector used for use by the next shift. If a defect is detected, take out the affected packs and earmark them for evaluation. If something has changed since before the defect, a quick note helps the team to identify where investigations need to take place.

If multiple benches are performing the same order, compare the first packs of each bench. Before operators start, ask them to identify the location of the strap and the joint in the reference picture. This is particularly helpful when temporary personnel are working at different stations.

Conclusion

A good manual PP strapping station will provide operators with a clear pack to copy. Check the band/closure match, the tool match and demonstrate where the strap should be placed before the bundle moves off of the bench. A regular first pack inspection will ensure that each shift will detect any changes that can be corrected easily.

FAQ

Q1. Can PP strapping be applied manually to enclose small cartons?

It can be the actual option for light bundles. Test to see if boxes will support each other and to ensure that the completed bundle will remain stable when handled normally.

Q2. Are all PP straps able to be buckled or sealed with the same buckle/seal?

Apply a band closure approved for band and tensioning system. Ensure that the combination of the exactly sized straps is compatible.

Q3. When the strap is tightened, why does the carton's corner bend?

Band may be applied on a weak edge or the tension applied may be too tight for the pack. Revisit the "contact point, edge support, approved tool method.

Q4. Are the same work instructions to be used on the same cartons for two shifts?

They may share it if it is appropriate for both types of carton for the materials and application. If there are any differences in how any strap is positioned or set up on the reference for each pack, show them.

Q5. When is the first pack check repeated by the operator?

Repeat it after any change which might impact the result, like a new carton format, closure or tool. Before continuing, compare the first pack that is completed with the approved pack reference.