How to Save Money on Shipping - Part 2: Bundling and Shipments

Weight Matters
Freight and parcel carriers care primarily about two things - weight and size.  What they are generally not concerned with are the number of pieces being shipped.  This is another area where you can create significant savings.

Each item that requires a label qualifies as a "shipment."  Your shipping rates are determined based upon the size and weight of that shipment.  The charts below will illustrate the difference between shipping multiple single packages as individual shipments, or bundled packages as one shipment.  The red bar indicates the price to ship 1-6 boxes, each as an individual shipment (each has its own shipping label).  The green bar indicates the price to ship one bundle of 1-6 boxes as one shipment (only one shipping label is used, and all boxes are bundled together as one).
 

Shipment A - 11" x 14" x 4", 3lb Package(s)	Shipment B - 6" x 10" x 5", 6lb Package(s)
Shipment C - 13" x 16" x 6", 15lb Package(s)	Shipment D - 10" x 14" x 12", 19lb Package(s)

Depending upon the size and weight of each package, the shipment costs differ dramatically.  You'll notice that the per package price increases far more dramatically than does the cost when the same number of packages are bundled together to ship as one.  With Shipment A, a very lightweight package, the cost barely changes between 1 and 6 packages when they are bundled together, but increases significantly when they are processed as individual shipments.  As the packages get heavier, the difference eventually narrows, but is still significant.

As long as the bundle isn't so big that it warrants dimensional weight, oversize, or overweight charges (addressed in Part 3), bundling multiple boxes together as one shipment can be a significant means of saving shipping dollars.

How to Bundle
UPS and FedEx are very specific about how they want you to safely bundle your packages.  There are three ways to accomplish this.

Bundling with Strapping
The image to the right illustrates how the carriers recommend you strap your packages when bundling them.  They suggest two straps in each direction.  They also discourage the strapping from being used as handles.  This can lead to weakened or broken seals which can result in problems in shipping.

The most common material for these purposes is polypropylene strapping.  This material is available in a variety of widths and break strengths.  The strapping can be applied and sealed with manual tools, battery operated hand-held tools, pneumatic tools, or semi-automatic machines.  For more information about selecting the right strapping, visit our post on How to Select the Right Strapping Product.

Bundling with Tape
For those who will bundle infrequently, tape is an easier option than strapping.  It requires no special tools and is easily applied.  Parcel carriers still suggest that the tape be applied in the same pattern as the strapping example above.

While some carton sealing tapes will suffice, it is highly recommended that filament MOPP tape be used.  This tape most often comes in the form of filament or tensilized tapes.  Filament tape is simply a standard tape but with nylon filament threads running the length of the tape to give it added strength when bundling.  Tensilized tape is similar in construction, but the filaments are manufactured in to the tape and not visible, and they run both the width and length of the tape.  As with most tapes, it's important to use the appropriate thickness based upon the weight of the product being bundled.

Bundling with Stretch Wrap

Stretch wrap is similar to tape, but does not have any adhesive quality so it will not leave any residue or mar the boxes.  Bundling stretch wrap comes in widths of 2", 3" and 5".  It also should be applied like the strapping, with the stretch wrap being applied in both directions.  Bundling stretch wrap is probably the easiest to apply of the three methods suggested here.  Stretch wrap strength is measured by gauge, or thickness, with the higher number indicating the thicker wrap, and subsequently that which is applicable for heavier weight bundling operations.  Lightweight bundling applications can use lower gauge wraps.

There are three handle types available with bundling wrap.

• Standard Core - Comes on a 3" core and ships with one plastic plug-in handle per box
• Extended Core - Comes on a 1" extended core so that each roll has its own built-in handle
• QuikWrap - Comes on a 1-3/4" core and a specialized plug-in handle that swivels around its own core

No matter which of these bundling wraps you choose, the actual wrap is the same - only the core and handle are different.  More information on stretch wrap and bundling wrap can be found on our post, How to Select Stretch Wrap.

No matter which method you choose, depending upon your unique needs, bundling your shipping is a clear way to save a potentially significant amount on your shipping.  If you have multiple pieces going to the same destination, this is an option you will want to consider.

If you have any questions about which option may work best for you, or what product will work best, please contact us and we will be happy to help you.

For other ways to save money on shipping, look at How to Save Money on Shipping - Part 1: Service Level and Part 3: Surcharges and Other Charges.

How to Select the Right Strapping Product

There are four primary types of strapping available in the industrial market - steel, polypropylene, polyester, and cord.  Each has its own strengths and applications.  The following information will help you determine what type of strapping will work best for your needs and help you understand the difference between them.

Steel Strap
Steel strapping is the strongest of all the strapping materials.  It is recommended where high strength is necessary, low elongation (stretch) is important, and where the product may be sharp or hot.  Steel strapping is sealed using mechanical seals and notch (sealless) type joints.  While it is still the preferred alternative in many industries, the market for steel is declining, largely because it can be dangerous to work with (presenting sharp edges) and is difficult to recycle.
Advantages -  High strength, low elongation
Disadvantages - Relatively expensive, sharp edges, difficult to recycle
Applications - Sharp or hot products, steel, rail car, heavy construction

Polypropylene Strapping
Polypropylene strapping is the most commonly used and least expensive of all strapping materials.  It is light, easy to apply, and easy to recycle.  It's primary characteristics are high elongation (stretch) and elongation recovery.  It has, however, a low retained tension.  Polypropylene strapping is available in hand grade and machine grade, and can be sealed with buckles, seals, heat seals, or friction welds.  Worth noting, machine grade strapping can be used with manual tools, but hand grade strapping should not be used in a machine application.  Polypropylene is used in all automatic strapping machines and almost all stand-alone arch strapping machines.
Advantages - Most cost effective, lightweight, easy to apply, easy to recycle, high elongation, high elongation recover
Disadvantages - Low retained tension, potential to split
Applications - Light duty palletizing, unitizing, carton closing, bundling

Polyester Strapping
Polyester (or PET) is the most rigid of the strapping options.  It has significantly less elongation than polypropylene and retains tension over a longer period of time.  Polyester strap is nick resistant and is sealed with seals, heat, or friction welds.

Polypropylene (L), Polyester (R)

Since polyester strapping offers the highest strength and greatest retained tension of all the plastic strapping, it is often used on heavy duty loads that need high initial tension along with high retained tension during handling and storage.  Additionally, competitive pricing and performance characteristics have motivated many steel strapping uses to switch to polyester.  Polyester strapping is available in both machine grade and hand grade and is easy to dispose of and recycle.
Advantages - Most rigid, long tension retention, high strength, nick resistant, easy to recycle
Disadvantages - Less elongation than polypropylene
Applications - Empty cans and bottles, lumber, heavy/rigid pallet loads, steel replacement

Discerning Polypropylene from Polyester Strapping
Plastic strapping, in general, is often referred to collectively as "poly strapping."  This can create much confusion when attempting to order or obtain quotes since poly strapping could be either polypropylene or polyester.  Polypropylene strap is typically embossed (per the graphic above) and feels more like plastic.  It is usually a more of a matte finish.  Polyester is a glossy, smooth strap.  Polyester strap does not resemble polyester fabric in any way.  Since polypropylene is the most common plastic strap option, "poly strapping" will generally refer to polypropylene.  Still, it is important to be able to differentiate between the two in order to be certain you or your customer procure the correct material.

Cord Strapping

Cord strapping is available in both polyester and rayon, and comes in two basic forms - uniline and cross woven.  Cord is used only in manual applications and is sealed using buckles, seals, or is tied.  Polyester cord offers excellent resistance to moisture and is frequently used in outdoor applications.  Heavy duty polyester cord is frequently replacing steel in lumber applications. 
Advantages - Can be manual applied with no tools, moisture resistant
Disadvantages - Poor elongation, difficult to recycle
Applications - Steel replacement, agricultural, boating

The chart below illustrates the advantages of each type of strapping and compares the relative performance of each.  It also indicates what types of applications will work with that material.  Definitions of these characteristics can be found below.

Strapping Tools and Options
Be careful when selecting any strapping tools.  Some tools can be used on any plastic strap, some can only be used on polyester or polypropylene, and some can only be used on one type of strap.  Most are also limited to a certain size range (width and/or thickness).  There are no tools that cover every strap size and/or type.  Tools for steel strapping are always exclusive to steel strap only.

Hand Application 
No tools are required, only buckles that the strap is wound through.  The strap is hand-tightened.
Advantages - No tools required, most convenient
Disadvantages - Maximum working range of the strap is not achievable
Strap Type - Cord only

Manual Tools
Requires a tensioner, a sealer, and seals.  This is the most common way of applying strapping.
Advantages - Allows the achievement of the maximum, or near maximum, working range of the strap; secure
Disadvantages - Requires multiple tools and the appropriate seals
Strap Types - All: Polypropylene, polyester, cord, steel

Battery Operated Tools
Combines all the necessary operations in one tool - tensioning, sealing, and cutting.  Offered in varying strengths to accommodate the unique needs of the user.
Advantages - Consolidates all strapping functions in to one tool, portable, efficient, requires no seals, enables achievement of a specific amount of tension
Disadvantages - Can be lost or damaged due to their portability, least durable of the powered tools
Strap Types - Polypropylene, polyester

Pneumatic Tools

Combines all the necessary operations in one tool - tensioning, sealing, and cutting.  Offered in varying strengths to accommodate the unique needs of the user and the type of strapping.
Advantages - Consolidates all strapping functions in to one tool, efficient, powerful, requires no seals, enables the achievement of a specific amount of tension
Disadvantages - not portable (requires a compressed air source), heavier than battery tools
Strap Types - Polypropylene, polyester, steel

Machines

There are a variety of strapping machines depending upon your needs.  Low volume machines include semi-automatic arch and table-top machines.  They extend in to high-volume automatic machines custom made for your application.
Advantages - Consolidates all strapping functions, fast, efficient, automatic or semi-automatic, requires no seals, can integrate with an assembly line or conveyor system, allows achievement of a specific amount of tension
Disadvantages - The most expensive strapping option, relatively large footprint, require and power and/or pressurized air source, limited as to the size/weight of the box that they can strap
Strap Types - Polypropylene (smaller machines), polypropylene or polyester (larger machines)

Strapping Characteristics and Definitions
General Terms:
Elongation - The amount of stretch in the strap as tension is applied
Elongation Recovery - The strap's ability to return to its original state after tensioning
Hand Grade Strapping - Designed to be applied by hand with manual, electric or pneumatic tools.  Cannot be used in a semi-automatic or automatic strapping machine.

The following terms are necessary to understand when purchasing/selecting strapping:
Break Strength - The amount of force, in pounds, required to break the strap
Core Size - the diameter and depth of one coil of the strap. This must correspond to the dispenser or machine being used with the strapping.
Thickness - this is the physical thickness of the strap, measured in fractions of an inch, such as .020"
Width - the physical width of the strap, it must correspond with the tools or machine being used to apply the strap
Color - the color of the strap is completely subjective and has no impact on the performance of the strap
Embossing - the diamond-shaped textured pattern applied to most polypropylene strapping.  It enhances split resistance, improves stiffness characteristics, and increases joint efficiency.
AAR Approved - AAR is the American Association of Railroads and AAR approved strapping is strapping that has been approved by AAR and bears their seal for safely transporting bundled material on rail cars

Contact us with any additional questions you may have and we will be happy to assist you in determining the type of strap needed for your unique application.