Strapping Tape vs PP Strapping vs PET Strapping: Which Should You Use?

Published on April 12, 2022

So here is where most operations get confused. The term “strapping tape” is used to describe two very different products. The first is a polypropylene adhesive tape available in narrow widths, applied by hand or machine, and closed with buckles that bundles, reinforces, and secures lighter loads quickly without needing tensioners, sealers, or strapping machines. The second is the broader category of strapping systems PP strap coils, PET polyester, composite, poly woven, and steel used with dedicated tools and machines for heavier industrial loads. Both have a place in Australian operations. Here is how to understand each one, when to use which, and how to choose the right specification for your load. The global sealing and strapping packaging tapes market was valued at USD 26.31 billion in 2025 and is forecast to reach USD 40.58 billion by 2034. Towards Packaging 2025

Strapping Tape: What It Is and Why It Is Not Standard Packaging Tape

Five Reasons Australian Warehouse Operations Use Strapping Tape

⚡No tools or machinery required

Strapping tape applies by hand and closes with a simple poly buckle. There is no tensioner, sealer, or crimping tool needed. This makes it the fastest and most practical solution for low to medium volume operations where a strapping machine is not justified.

💰Low cost per application

What if you need reliable load security without the capital investment of a strapping machine? Strapping tape is the most cost effective strapping solution for operations bundling lighter loads. No machine purchase, no maintenance cost, and no operator training beyond basic application technique.

📦Versatile across load types

Now here is where strapping tape earns its place on the warehouse floor. It secures bundled products together, reinforces the base of cartons against bursting, holds multiple cartons together for a single shipment, and wraps around palletised lightweight goods for domestic delivery. One product covers multiple securing applications.

🔄Compatible with hand dispensers and machines

Gateway Packaging’s strapping tapes can be applied manually or via machine, giving operations the flexibility to scale from hand application to automated processes as volume grows. They close with poly buckles available separately through the strapping accessories range.

Gateway Packaging Strapping Tape Range: 12mm, 19mm, and 25mm

If we look at Gateway Packaging’s strapping tape range, it covers three standard widths each suited to a different load size and bundling requirement. All are made from top grade polypropylene in black, suited to everyday warehouse strapping requirements, and available for same day despatch from Australian stock.

For heavier loads or applications requiring wider coverage, the 25mm x 66m strapping tape product code 11510 in black provides maximum width for general applications including bundling, palletising, and securing heavier lightweight packages. All Gateway strapping tapes close with poly buckles available from the seals and buckles range, and are compatible with polypropylene strapping tools and dispensers for operations that need a more consistent application process.

💡 But wait. When does strapping tape reach its limits? Here is the thing about strapping tape it is a polypropylene adhesive product suited to light to medium loads on domestic routes. What if your load is over 200kg, going interstate or export, exposed to outdoor storage, or made up of rigid construction materials with sharp edges? That is where strapping tape is not the right specification and broader strapping systems PP strap coils, PET, composite, or steel take over. Here is how those work and how to choose between them.

Beyond Strapping Tape: The Six Industrial Strapping Types Explained

When loads exceed strapping tape capacity, six strapping system types cover Australian industrial applications. PP polypropylene coils suit general warehouse and domestic freight. PET suits heavy loads, outdoor storage, and export. Filament tape suits carton reinforcement needing near strapping strength. Composite suits large irregular loads. Poly woven suits medium heavy loads without metal risk. Steel suits maximum tension industrial applications.

Polypropylene (PP) Strap Coils

General purpose light to medium loads widths 5mm to 19mm

Now when strapping tape is not enough but a full PET or steel system is more than needed, PP strap coils are the next step. Applied with a hand tensioner and sealed with metal open seals or poly buckles, PP strap provides consistent tension on general palletised loads. Available in 12mm x 1000m for loads up to 90kg, and 19mm x 1000m for loads up to 250kg. Compatible with semi automatic and fully automatic strapping machines as well as Tenso® battery powered tools.

Polyester (PET) Strapping

Heavy loads outdoor storage export freight

So what does an operation use when PP strap is not strong enough? PET polyester strapping. The recognised alternative to steel strapping lighter, non rusting, UV resistant, and available in smooth and embossed variants. Smooth PET uses serrated metal seals with a manual tensioner and crimping tool. Embossed PET welds directly with a battery friction weld tool no seals needed. Break strength ranges from approximately 530kg at 16mm to over 960kg at 25mm, making PET the correct specification for heavy construction loads, export freight, and outdoor storage. NHVR Load Restraint Guide 2025

Filament Tape

Carton reinforcement bundling pallet unitising

Here is the thing about filament tape. It bridges the gap between strapping tape and strap systems. Fibreglass filaments embedded in its polypropylene backing give it near strapping tensile strength in a tape format no tools or buckles needed. One way filament tape suits linear bundling in 12mm to 48mm widths. Two way cross woven suits loads that shift in any direction in 18mm to 48mm widths. Used in food, electronics, automotive manufacturing, and oil and gas industries.

Composite Strapping

Large heavy irregular loads harsh environments

If we look at loads where neither PP nor PET performs at its best very large loads, irregular shapes, extreme temperature variation composite strapping is the specification. Tenso® composite strapping is made from co extruded high tenacity polyester yarns in a polymer coating. Unlike PET and steel, it does not break from a single point of impact due to its elasticity. Non abrasive suits painted, coated, and delicate surfaces. Requires galvanised buckles for reliable joint performance.

Poly Woven Strapping

Medium-heavy loads non metallic alternative to steel

What if an operation needs steel level strength without metal contact risk? Poly woven strapping provides high tensile strength without sharp edges, rust, or the handling safety concerns of steel. Available in 15mm and 19mm widths in 500m to 1000m lengths. Applied with a tensioner and secured with phosphate coated wire buckles. Compatible with the Heavy Duty Poly Woven Strapping Tensioner that tensions and cuts with the same tool.

Steel Strapping

Maximum tension construction and heavy industrial

Later in the strapping selection process, when every other material has been assessed and the load requires maximum tension without elongation, steel strapping is the specification. Used in construction, heavy manufacturing, and metal fabrication where load weight and rigidity demand permanent tension. Available in ribbon wound and rope wound configurations with steel seals. Always use safety gloves and eye protection steel strapping snapback is a documented WHS hazard when strap breaks or is cut under tension. Safe Work Australia

Strap Width and Break Strength: How to Match the Right Specification to Your Load

So what is the practical sizing framework? Break strength should be 1.5 to 2 times the per strap load weight to provide an adequate safety margin. A 400kg pallet with two straps means each strap carries 200kg each strap therefore needs at least 300kg break strength at 1.5 times. PET at 15mm provides 350kg to 450kg break strength correct. PP at 15mm provides 180kg to 220kg not enough for that load. Here is the width to load weight guide for Australian operations:

What Is the Difference Between Tensile Strength and Break Strength in Strapping?

Here is the terminology distinction that matters when comparing strapping specifications. Tensile strength is the maximum resistance a material offers before failing under a gradually increasing controlled test load. Break strength is the force required to break the strap under a sudden impact which is what actually happens in transit when a load shifts or drops. Break strength is always the more relevant figure for real world Australian freight conditions. PET strapping break strength ranges from approximately 530kg at 16mm to over 960kg at 25mm width. Always compare break strength figures, not tensile strength figures, when selecting a strap for a specific load.

What Seals and Buckles Does Each Strapping Type Require?

But wait the strapping or tape is only half of the load security specification. The seal or buckle joining the ends is the weakest point in the system and must match the material exactly. Here is the matching guide. Strapping tape closes with poly buckles no tools required. PP strap coils use metal open or closed seals with a hand tensioner and crimper, or poly buckles for lighter applications. Smooth PET strap uses serrated metal seals crimped with a tensioner and sealer tool. Embossed PET uses no seals a battery friction weld tool welds the joint directly. Composite strapping requires galvanised buckles phosphate coated buckles cause tearing at the joint. Poly woven uses phosphate coated wire buckles to increase friction. Steel strap uses open or closed steel seals matched to the strap width. Gateway Packaging’s full seals and buckles range covers every strapping type and width.

Why Are Edge Protectors Essential When Using Strapping on Palletised Loads?

What if the strapping fails not because the strap broke but because the load cut through the strap? This happens when strap routes over a sharp corner wooden pallet edge, steel tube end, brick edge, corrugated carton corner without edge protection. The strap concentrates tension at the corner and the load material cuts through. Edge protectors distribute strap tension across a wider surface area, preventing both strap failure and surface damage. The rule: any pallet where the strap routes over a corner harder than the strap material requires edge protectors. Gateway Packaging’s plastic edge protectors at 62mm length and 35mm x 35mm hold straps up to 19mm with moulded ridges preventing slippage.