You can pick the perfect box and the strongest tape, but if your pallet loads aren’t strapped correctly, product still arrives crushed, shifted, or scattered across a trailer floor. Strapping (also called banding) is the workhorse that holds palletized freight together through forklifts, dock drops, and long highway miles. Here’s a practical rundown of the strapping types, tools, and techniques that keep Chicagoland shipments intact.
The three main types of strapping
Most warehouses run one of three materials, and choosing the right one comes down to load weight and how much “give” you need.
- Polypropylene (PP) — The lightweight, economical choice for bundling, carton closing, and light unitizing. It stretches and recovers a little, which is fine for light to medium loads but not for anything heavy or sharp-cornered.
- Polyester (PET) — The strongest plastic strapping, with high retained tension. PET is the go-to replacement for steel on most palletized loads because it absorbs impact and keeps tension as the load settles.
- Steel — Reserved for the heaviest, rigid, sharp-edged, or high-temperature loads like coils, bar stock, and metal castings. It has almost no stretch, so it holds rigid freight tightly but can snap under sudden impact.
Match the strap to the load
Strapping is rated by width, thickness, and break strength. A common mistake is over-buying strength you don’t need, or worse, under-strapping a heavy pallet to save a few dollars. As a general guide: light bundling jobs do well with 3/8″ to 1/2″ polypropylene, medium pallet loads with 1/2″ to 5/8″ polyester, and heavy industrial freight with 5/8″ or wider polyester or steel. When in doubt, factor in load weight, edge sharpness, transit distance, and how much the load might settle in transit.
Don’t forget the tools and accessories
Strapping only works as well as the tools tensioning it. You’ll need a tensioner to pull the strap tight, a sealer or buckles (for steel and some PP), and either metal seals or a friction-weld/battery-powered tool for plastic strapping. Battery-powered combination tools tension and weld in one step and are a major time-saver for high-volume lines. Just as important are edge protectors, which spread strap tension across box corners so the band doesn’t cut into your cartons or product.
Strapping technique that actually holds
- Apply at least two straps per pallet, more for tall or unstable loads, and run them over the corners where the load is most likely to shift.
- Use edge protectors on every corner the strap crosses.
- Tension consistently. Too loose and the load shifts; too tight and you crush the product.
- Combine strapping with stretch film for unitizing. Film contains the load, strapping anchors it to the pallet.
- Inspect seals and welds. A bad joint is the most common failure point.
Stock it before you need it
Running out of strapping mid-shift stops your dock cold. That’s where a local supplier matters: KMS Distributing stocks polypropylene and polyester strapping, seals, buckles, tensioners, edge protectors, and the rest of your unitizing supplies for warehouses across Chicagoland. If your loads are unusual or high-volume, ask about bulk ordering to lock in pricing and keep your line stocked. You can also browse the full catalog of strapping and packaging gear in our online shop.
Need strapping, tools, or a full unitizing setup fast? Call KMS Distributing at (847) 630-7502, email orders@kmsdistributing.com, or browse 20,000+ products at our online shop. Enjoy free Chicagoland delivery on orders over $1,000, with most in-stock orders placed before noon arriving the next business day.
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