With a lifting aid, you can handle an average of two to three times more boxes per hour than by hand. While an employee typically handles between 60 and 120 boxes per hour when lifting by hand—depending on the weight and working height—an ergonomic lifting aid can increase that number to 150 to 300 boxes per hour. The difference becomes even greater as boxes get heavier or need to be placed at hard-to-reach heights. In this article, we answer the most frequently asked questions about productivity, costs, and choosing the right box-lifting aid.
How many boxes do you process manually per hour?
When processing boxes manually, the average processing speed ranges from 60 to 120 boxes per hour. This number drops rapidly as boxes become heavier, the working height becomes less favorable, or the employee becomes fatigued. After a few hours of intensive lifting, the pace slows noticeably, which significantly reduces daily output.
Moving boxes manually is physically demanding, especially when boxes weigh more than 10 kg or when they need to be placed at shoulder height or higher. The strain on the back increases exponentially with repetitive movements performed in awkward positions. This not only results in a slower processing speed but also in a higher risk of injuries, increased absenteeism, and reduced long-term employability of employees.
Concentration also plays a role. Fatigue leads to an increase in errors, which results in damaged products or incorrect placement. As a result, manual processing of boxes is not only slower but also less reliable as the day progresses.
How many boxes per hour can you process using a lifting aid?
With an ergonomic lifting aid, you can handle an average of 150 to 300 boxes per hour, depending on the type of lifting aid, the weight of the boxes, and the work environment. That represents an improvement of 50 to 150 percent compared to manual labor. In addition, the handling speed remains stable throughout the entire workday because the physical strain is greatly reduced.
A lifting aid takes over the lifting and placement work, allowing the employee to focus on positioning and checking. This makes the process faster, more precise, and less tiring. This advantage is particularly significant when handling boxes, since boxes are often processed in large volumes and at varying heights.
With vacuum lifters or motorized lifting aids, the benefits are greatest when handling heavy or unwieldy boxes. But even with lighter boxes, a lifting aid ensures a faster and more consistent pace, since the employee expends less energy per operation.
What are the main factors that affect processing speed?
The processing speed for handling boxes is determined by the weight and dimensions of the boxes, the working height, the layout of the workstation, and the type of lifting aid. Each of these factors can have a positive or negative impact on output, whether the work is done manually or with a lifting aid.
- Weight of the boxes: Heavier boxes reduce the manual handling rate more significantly and make a lifting aid pay for itself more quickly.
- Working height: Positions above shoulder height or below knee height are physically the most demanding and take the most time when performing manual work.
- Workplace layout: Short walking distances and a logical workstation layout increase speed regardless of the method used.
- Type of lifting aid: A vacuum lifter works differently than a motorized lifting arm. Choosing the right equipment plays a key role in determining how much profit you make.
- Employee experience: A well-trained employee works faster and more safely, whether working manually or using a lifting aid.
A thorough analysis of the workstation is therefore essential before selecting a lifting aid. What works well at one location may not be the best choice at another.
When is a lifting aid a good financial investment?
A lifting aid is financially worthwhile when the gains in productivity, savings on absenteeism due to illness, and lower labor costs combined exceed the investment cost. In practice, companies that handle large volumes of boxes on a daily basis see a payback period of six months to two years, depending on the intensity of use.
The financial calculation goes beyond just the purchase price. Taking the following factors into account provides a more realistic picture:
- Productivity gains: More boxes per hour means higher output with the same number of employees, or the same output with fewer employees.
- Reduced Absenteeism: Back pain and RSI-related absences are costly. An ergonomic lifting aid has been shown to reduce this risk.
- More flexible staffing: Employees who are subjected to less physical strain can remain employable for longer and in a wider range of roles.
- Less product damage: A lifting aid ensures more stable and precise handling of boxes, which reduces damage.
The payback period is typically shortest when dealing with high volumes, heavy boxes, or a workplace involving many repetitive movements. Be sure to check out our reference projects for concrete examples of how companies have made this decision.
What type of lifting aid is best suited for handling boxes?
Vacuum lifters and motorized lifting aids are the most commonly used solutions for handling boxes. The choice depends on the weight of the boxes, the type of packaging, the working height, and the required mobility on the work floor.
Vacuum lifters for boxes
Vacuum lifters are ideal for cardboard boxes with a smooth, solid surface. They grip the box using suction cups and lift it without requiring any effort from the operator. This process is exceptionally fast and precise, especially when placing boxes on pallets or in racks. You can find more information about this type of equipment in our vacuum lifters and hoists section.
Motorized lifting aids and mobile lifts
For heavier boxes or situations that require greater mobility, motorized lifting aids and mobile lifters offer a suitable solution. They can handle heavier loads and are often more versatile across different workstations. When placing boxes at great heights, they provide added safety and precision.
How do you measure productivity gains after implementing a lifting aid?
You can measure the productivity gains achieved after introducing a lifting aid by comparing the number of boxes processed per hour before and after implementation, supplemented by data on absenteeism, error rates, and employee satisfaction. A comprehensive assessment combines quantitative output with qualitative indicators.
In practical terms, you start with a baseline measurement: over the course of a week, record the average number of boxes per hour per employee, the number of errors, and the pattern of physical complaints. After implementation, repeat this measurement following a two- to four-week break-in period, so that employees are familiar with the new device.
Useful measurement points include:
- Average number of boxes processed per hour per employee
- Total daily output of the department
- Number of sick days related to physical symptoms
- Percentage of damaged or incorrectly placed boxes
- Employees' Subjective Assessment of Their Workload
An increase in output, combined with a decrease in complaints and errors, is a clear sign that the lifting aid is proving its worth. Systematically tracking these figures also helps to accurately calculate the payback period.
How Logitrans Handling Helps Process Boxes
We guide companies step by step in increasing productivity and reducing physical strain when handling boxes. Our approach is practical and tailored to each client’s needs:
- Free Workstation Analysis: We analyze your current work process and identify the bottlenecks, from work height to volume and weight.
- Customized Product Recommendations: Based on the analysis, we select the most suitable type of lifting aid from our extensive product range, from vacuum lifters to mobile lifting solutions.
- Testing in the demo room: In our demo room in Drongen, you can try out the machine with your own boxes so you know exactly what you're buying.
- Training and Installation: We ensure proper installation and train your employees so they can use the equipment safely and efficiently.
- Maintenance Contract: Through our maintenance contract, we keep your lifting aid in top condition and help prevent unexpected downtime.
Would you like to know how much productivity your specific situation could gain from a lifting aid? Contact us for a no-obligation consultation or a free workstation analysis.
