Fragile Strength: Why Reusing Plastic Strapping Tapes Is a Risk Not Worth Taking

Maria Isabel Salinas
3 days ago
2 min read

In the fast-paced world of logistics and packaging, plastic strapping tapes play a silent but vital role—securing goods, stabilizing pallets, and ensuring safe transport. However, recent research conducted by Dr.-Ing. Marianne John and Thomas Wagner from the Fraunhofer Institute for Microstructure of Materials and Systems IMWS reveals a critical limitation: these tapes are not designed for reuse—and attempting to do so poses significant risks.

Unseen Damage, Measurable Risk

The study, presented on April 25, 2025, systematically examined the damage behavior of strapping tapes made from both polypropylene (PP) and polyethylene terephthalate (PET), including those containing recycled content. Using recognized industry standards such as EUMOS 40509 and ISTA 1E, researchers subjected the tapes to horizontal stability, inclined impact, and vertical vibration tests.

The results showed a marked drop in tensile strength, especially in the welding areas, where stress concentrates during use. In PP tapes—both virgin and with 30% recycled content—strength dropped by up to 60% after use. Even PET straps, known for their durability, exhibited significant weakening after repeated welding or under stress.

Temperature Stress Adds Another Layer of Complexity

In addition to mechanical stress, the researchers investigated how extreme temperature fluctuations (from 40°C to -30°C) impact strap performance. These conditions mirror real-world situations like loading a truck in sub-zero climates after indoor strapping.

Key findings included:

Thermal cycles lead to stress relaxation, reducing the strap’s holding power.
Residual stresses from initial use are retained, especially in PET straps.
Pre-existing damage from first use is invisible and not traceable, making reused straps unreliable.

Final Verdict: Reuse Not Recommended

The conclusion from the Fraunhofer IMWS team is unequivocal: plastic strapping tapes should not be reused for transport purposes.

“Reuse is highly not recommended due to the lower mechanical properties of the welding area,” the study emphasizes.

The researchers warn that, despite good intentions around sustainability, reusing these tapes can compromise safety, especially in critical logistics applications.

The Path Forward: Recycle, Don’t Reuse

While the findings may seem discouraging from a sustainability perspective, they highlight the need for better design and material innovation—straps that are not only recyclable but also safe and reliable in a circular economy.

This research provides a clear direction for manufacturers and transport companies alike: focus on safe, one-time-use straps made from recyclable materials, and invest in systems that ensure proper recovery and recycling after use.

Read the Full Study

To explore the data, test results, and methodology in detail, you can read the complete report here:👉 Access the full document

About the Authors

This study was carried out by Dr.-Ing. Marianne John and Thomas Wagner at the Fraunhofer Institute for Microstructure of Materials and Systems IMWS, based in Halle (Saale), Germany. Their work continues to inform industry standards and best practices in packaging, materials science, and transport safety.

For further details, visit: www.imws.fraunhofer.de