Pallet Handling And Ergonomics To Minimize Risk And Boost Productivity


Handling loaded pallets are the most common, difficult, and concerning zone for the ergonomics of every warehouse operation. Especially, with labor shortages and escalated safety concerns handling pallet loads and pallets is a top priority for every warehouse manager.

Investment in ergonomics is because the concept is practical for multiple reasons.

  • Reduces workplace injury rates.
  • Lessens worker’s compensation costs.
  • Less labor dependence.
  • Increases productivity.

Poor ergonomics tend to impact productivity directly. Nevertheless, good ergonomics inclines to increase accuracy and speed.

Aim of ergonomic pallet handling

A loaded pallet poses several ergonomic challenges. Using the best practice will allow the tasks to adjust to workers instead of workers modifying to the task at hand.

  • Loaded and empty pallets are heavy.
  • Pallets are generally stacked on top of one another. So, the upper, middle, and lower boxes are positioned in different reach zones.
  • Workers need to work at multiple angles and sides to access the pallets.
  • Pallets move from one area to another or through a variety of processes within the warehouse. So, they need to be accessed by different people at different times.

The best method to adjust the body and handle palletized loads is to incorporate automated and mechanical solutions. It can help to initiate and lessen the musculoskeletal stresses that even help to make repetitive processes conclude easily and quickly. Generally, pallet handling is integral in every sector for receiving, stacking, storing, shipping, and processing. Therefore it is essential to find ergonomic pallet handling solutions.

In practice, the action to remove or add loads to the pallet is an ergonomic challenge. High-speed, robotics, and the automated palletizing system will lessen the burden but for some operations, these are not viable, so choose point-of-use solutions. Mix various technologies and equipment for better ergonomics. It includes pallet inverters, balancers, lift tables, rotators, and cranes. All these help the load to adjust to the worker’s body instead of the worker’s body adapting to loads.

Pallet inverters

TopIndustries is a leader in designing advanced pallet inverters. When there is a need to switch a full-loaded pallet to a new pallet the high-quality pallet inverter is a superb solution. The task is attained without restocking.

The equipment is more ergonomic and works faster. You can handle broken pallets without completely unloading and reloading merchandise. Pallets can be changed from wooden to plastic or vice versa quickly. It even allows you to access the load that lies near or on the bottom layer.

Pallet transportation

Pallet stackers are an ergonomic transporting method. Walk behind the stacker machine, which eliminates the burden of moving the loads with muscle power. The equipment can lower or raise the loads or containers to be stocked or accessed from ergonomic heights.

According to OSHA, split the load if it is more than 50 lbs. if workers move them using a pallet jack. Pushing is actually more ergonomic than pulling, so it is recommended. There are the manually handled, transport dollies loaded using forklifts. However, for manual transport follow the not more than 50 pounds protocol for better safety.

Check how TopIndustries use power conveyors in the assembly line on Twitter!