What is ErgoPack?

ErgoPack is a range of pallet strapping machines designed to improve worker safety, process efficiency and pallet stability.

ErgoPack is an innovative, yet simple solution for strapping pallets. The portable machine semi-automatically dispenses, tensions and welds strapping around most pallet loads.

How does ErgoPack strapping work?

The machine is simple and efficient, with a the X-pert line range having a touchscreen panel to operate from. Simply position the machine in front of a palletised load for the ‘ChainLance’ to feed strap through the base of the pallet and up the back, over the load, into the operator’s hand. There is no need for the operator to walk around the pallet or bend down. The integrated strap lifter then raises the strapping to the operator, so that the sealing head can tension the strapping and weld the two together.

Benefits of ErgoPack

Improved worker safety

Many health and safety risks in warehouse operations come from poor manual handling process, which results in businesses facing employee ill health and absence. For example, in the UK, the Health & Safety Executive (HSE) found that 40.1 million working days were lost due to work-related ill health and non-fatal workplace injuries in 2024/25. The research shows employees miss an average of 14 days yearly due to work-related musculoskeletal disorders.

So how does this relate to strapping pallets?

Strapping pallets can cause musculoskeletal disorders by poor manual handling. Manual handling involves lifting, carrying, pushing or pulling on an object – movements required in traditional pallet strapping. Although it does not cause immediate harm, strain worsens over time as the task is repetitively completed, or done without any rests in-between.

Additionally, the HSE recognises stooping down to reach something, and repetitive work using the same movement as particularly hazardous tasks. Workers consistently perform both these tasks when strapping pallets, and this is where ErgoPack provides an effective solution. To address this, ErgoPack’s own findings suggest that for a business securing pallets that require a total of 50 strapping cycles, an ErgoPack machine will remove the need for operators to bend down 25,000 times, and walk around pallets 12,500 times each year! Consequently reducing the amount of potential musculoskeletal disorders.

ErgoPack’s ergonomic design improves efficiency and comfort in workplace, while reducing risks like trip hazards by ensuring straps don’t trail around the pallet.

Increased efficiency and throughput

Process efficiency increases as a result of ErgoPack reducing the time required to apply strapping to pallet loads.

The time needed to strap each pallet is cut by on average 67%. Where manual strapping typically requires two minutes per pallet, the machine takes just 40 seconds. For example, in applications requiring 50 strapping cycles per day, ErgoPack creates a time saving of around 70 minutes per day, adding up to 24.5 hours a month.

As mentioned earlier, it also lowers injury risk, which in turn leads to fewer absences and increased efficiency and productivity.

Confirmed pallet stability

Load stability and security improve because ErgoPack correctly tensions and welds strap into place.

Moreover, using an ErgoPack machine helps ensure pallet stability for every load. The user-friendly touchscreen on the X-pert range of machines allows operatives to programme the correct tension according to load sizes, weights, product type and storage or transportation requirements.

The machine is also electronically adjustable to operate at different heights and pallets widths, suiting different load sizes.

Furthermore, ErgoPack strapping machines offer a range of other benefits too. The line-laser helps operatives position the machine correctly in front of each pallet. In addition, the fully integrated sealing head welds the straps securely and precisely.

Wessex Packaging is GB’s official distributor of ErgoPack

Wessex Packaging is the official distributor for the German-made ErgoPack pallet strapping system in Great Britain. ErgoPack is trusted by businesses across the warehousing, logistics and wholesale sectors, as well as any organisation using pallets and strapping. Invented and founded in Germany 25 years ago, ErgoPack is quality designed, engineered and manufactured in Lauingen, Germany…bringing a reassurance to all customers. To see the benefits of this machine in action, you can book a free demonstration with our team.

Below we’ve answered some of the most common questions about ErgoPack…