Automated Strapping Solution for Vacuum Packed Foam Blocks

Project Overview

FROMM Packaging Australia recently partnered with one of Australia's leading foam product manufacturers, to upgrade their packaging operations with a new, fully automated strapping line. 

The project involved the design, manufacture and installation of an advanced automatic strapping solution featuring the latest FROMM technology to integrate with a new complete packaging line from an international OEM (original equipment manufacturer). FROMM were selected due to superior technology, local technical expertise and the proven reliability of the FROMM team.

The goal was to enhance process performance, reduce downtime and ensure reliable and secure load containment for products that can expand after strapping. 

The FROMM Solution

FROMM supplied and commissioned a high speed automatic strapping line, purpose-built to handle large, vacuum packed foam blocks.
The system includes a customised FROMM PM101000 Strapping System designed to accommodate oversized foam packs. Featuring a FROMM MH550 strapping head to ensure precise tension and reliable seals that maintain pack integrity under compression and expansion forces. 
The new system is designed with a telescopic strapping channel to handle varied pack heights (1000 mm - 2500 mm), and includes a strap dispenser for 20 kg PET strap coils. Together, these features deliver faster strap feeding, reduced cycle times, and improved overall throughput. Its robust mechanical design and integrated control system provide greater reliability and easier maintenance compared to the previous line. 
The entire system is supported by FROMM's local service network, ensuring quick response times and long term operational confidence. 

Challenges and Design Considerations

Strapping foam presents a unique challenge due to the expanding nature of the material. Once strapped, foam packs can expand post-compression, putting pressure on the seals and strap strength. This makes seal integrity, strap elongation and tension control critical to prevent pack deformation or expansion caused by strap failure. 
The FROMM system was specifically configured to manage this dynamic material behaviour, maintaining secure containment without damaging the product. 

Installation and Commissioning

Installation and full commissioning was completed within one week from unloading the machines onsite. The FROMM technical team managed the complete process, including setup, integration, testing and operator training. 
Training covered daily operation, maintenance routines and troubleshooting, giving the site team confidence in running and servicing their new equipment. 

Project Outcomes

The upgraded packaging line has improved operational efficiency and reliability. 
Key outcomes include;

• Faster cycle times thanks to the telescopic strapping channel system design
• Reduced maintenance downtime and greater system uptime
• Enhanced local support from FROMM's Australian technical team

These results demonstrate FROMM's capability to deliver reliable, purpose built equipment, making us a trusted partner for custom automatic strapping solutions across the Australian manufacturing industry.