Strapping Machine fault
Strapping Machine Not Tensioning Correctly
Incorrect strap tension — too loose, too tight or inconsistent — is usually caused by tension motor wear, worn gripper components, incorrect settings, or a strap specification that does not match the machine calibration.
Does this match your fault?
Common symptoms
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Strap feels loose on the load after strapping
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Strap is cutting into the product — over-tensioned
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Tension varies from cycle to cycle
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Machine shows tension alarm without completing cycle
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Strap breaks during tensioning
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Tension seems correct but seals are still weak
What causes this
Typical causes
Tension motor wear
The tension motor has worn over time and can no longer reach the set tension before timing out. Common on high-usage machines and often a gradual deterioration.
Gripper pad or jaw wear
The gripper that holds the strap during tensioning has worn pads or jaws. The strap slips before full tension is reached, giving a consistent under-tension result.
Tension setting incorrect
The tension setting has been changed — intentionally or accidentally — and is no longer appropriate for the strap specification or load type being run.
Strap specification mismatch
A change in strap width, thickness or material has altered how the machine achieves tension. Settings that worked for the previous strap may not be correct for the new one.
Before calling an engineer
What to check first
These are the practical checks worth trying before calling out an engineer. If none of these resolve the fault, or if the issue keeps returning, it needs a proper diagnosis.
01
Check the tension setting against the machine specification
Access the tension settings in the machine menu. Compare to the settings documented in the machine manual or your own records. Note any recent changes.
02
Test with a consistent load and observe the result
Run several cycles on an identical load and check whether tension is consistent or varies. Consistent under-tension suggests a mechanical issue; variable tension suggests a gripper or control issue.
03
Inspect gripper pads or jaws for wear
With the machine isolated, inspect the gripper components that hold the strap during tensioning. Worn pads or jaws will not grip the strap firmly enough to achieve set tension.
04
Check the strap specification
Confirm the strap width and thickness matches what the tension settings were calibrated for. A change in strap supplier or spec requires the machine settings to be reviewed.
When to call us
If any of these apply, call now
At this point, continued resets or workarounds are unlikely to resolve the underlying fault. A proper diagnosis is faster and cheaper than repeated call-outs for the same issue.
Tension motor audibly struggling or not reaching tension before timing out
Gripper pads visibly worn or damaged
Tension varies widely between identical cycles — gripper or control board issue
Related faults
More fault support
Report a Breakdown
Include the machine make and model, the fault you are seeing and any error codes. A photo of the display helps us triage faster.