For light boxes in order picking, a vacuum lifter is the most suitable lifting equipment. This device lifts boxes quickly, safely, and ergonomically using suction cups, without requiring the employee to exert physical force. Depending on the picking process and the work environment, other handling devices may also be relevant, such as guided lifting aids or semi-automatic systems. In this article, we answer the most frequently asked questions about lifting equipment for lightweight boxes.
What types of boxes are used in order picking?
In order picking, cardboard boxes of various sizes and weights are primarily used. The most common types are closed boxes, open trays, and boxes of varying dimensions, such as those used in e-commerce or distribution centers. The weight typically ranges from less than 1 kg to about 25 kg per box, depending on the industry and the product.
The variety of boxes is precisely what makes choosing the right material-handling equipment a challenge. In a food distribution center, boxes may be damp or slippery, while in the pharmaceutical sector, packages are often small and fragile. When handling boxes, stacking height, picking frequency, and available space also play an important role in determining the best approach.
Another relevant factor is whether the boxes are always the same size or vary significantly. Automation works best with uniform boxes. For varying sizes, a flexible, manually operated vacuum lifter is preferable.
What type of lifting equipment is suitable for lightweight boxes?
For light boxes in order picking, vacuum lifters are the most commonly used lifting equipment. Other suitable options include balance lifts, guided lifting aids, and semi-automatic systems for higher volumes. The choice depends on the weight of the boxes, the picking frequency, the work position, and the available space in the warehouse.
An overview of the most commonly used solutions:
- Vacuum lifters: ideal for boxes with a flat surface. They lift quickly, are easy to operate, and significantly reduce physical strain.
- Balance lifts and hoists: suitable when boxes need to be placed repeatedly at specific heights, such as at fixed workstations.
- Mobile lifters: useful when boxes need to be moved over longer distances within the warehouse.
- Semi-automatic systems: for high picking volumes where speed and consistency are priorities.
Browse our full range of handling equipment to get a good idea of the options available for each application.
How does a vacuum lifter for boxes work?
A vacuum lifter for boxes works by using suction cups that create a vacuum on the surface of the box. The employee positions the suction cup on the box, activates the vacuum with a lever or button, and can then effortlessly lift and move the box. When the suction cup is released, the vacuum is broken and the box is released.
The power of a vacuum lifter lies in its combination of speed and precision. A trained employee can handle dozens of boxes per hour with a vacuum lifter without experiencing physical fatigue. The suction cups are available in various sizes and configurations, tailored to the size and surface texture of the boxes.
Important note: Vacuum lifters work best on closed, flat, and non-porous surfaces. Boxes with perforations, rough cardboard, or sharply curved sides require customized suction cup designs or alternative lifting solutions. A good vacuum lifter is always tailored to the specific type of box being handled.
When should you choose a semi-automatic solution?
A semi-automatic solution is the right choice when picking volumes are high, the boxes are uniform in size, and the workspace offers sufficient room for an integrated system. Semi-automation combines human flexibility with machine speed and is particularly well-suited for distribution centers that want to reduce time-consuming, repetitive tasks.
Typical situations in which semi-automation offers added value:
- More than 200 picks per hour per employee
- Repeatedly lifting boxes to fixed heights or positions
- High Absenteeism Due to Physical Strain
- Growth in order volumes where manual work creates a bottleneck
Semi-automation does not mean that the employee is completely removed from the process. The system takes over the most labor-intensive or repetitive tasks, while the employee retains control and flexibility. This also makes it a realistic investment for companies that are not yet ready for full automation.
What are the ergonomic risks associated with manually lifting boxes?
Manually lifting boxes during order picking poses significant ergonomic risks. The most common complaints are back pain, shoulder pain, and muscle problems in the neck and arms. These are caused by repetitive lifting, poor posture—such as bending over or twisting—and working at uncomfortable heights.
In order picking, these risks are exacerbated by the high picking frequency. An employee who lifts hundreds of boxes a day—even if they weigh only 5 to 10 kg each—accumulates physical strain that, over time, leads to chronic health issues. This has a direct impact on absenteeism and productivity.
Ergonomic guidelines state that lifting above shoulder height or below knee height is particularly strenuous. These are precisely the situations that regularly occur when picking boxes from high racks or low pallets. Material handling solutions that optimize the work zone can significantly reduce these risk factors.
How do you choose the right lifting equipment for your picking process?
You should choose the right lifting equipment for lightweight boxes based on four criteria: the weight and size of the boxes, the picking frequency, the working height, and the available space. By assessing these four factors, you can make an informed choice between a vacuum lifter, a balance lifter, or a semi-automatic system.
A practical approach to organizing your decision-making process:
- Determine the weight and size: Lightweight, uniform boxes are ideal for vacuum lifters. Varying sizes call for a flexible solution.
- Analyze the picking frequency: for high volumes, a semi-automatic solution is worthwhile. For lower frequencies, a manual vacuum lifter is sufficient.
- Check the working height: lifting above shoulder level or below knee level always requires a mechanical lifting aid.
- Measure the available space: narrow aisles or limited workspace call for compact, maneuverable equipment.
A job analysis is a valuable tool in this regard. By thoroughly observing the workplace, issues come to light that are not apparent at first glance, such as awkward twisting movements or unnecessary extra steps.
How Logitrans Handling Helps with Lifting Equipment for Light Boxes
We specialize in ergonomic lifting solutions for every order-picking situation, from simple vacuum lifters to custom semi-automatic systems. Our approach is always focused on finding a solution that both reduces the physical strain on your employees and increases the efficiency of your picking process.
Here's what we do for you, specifically:
- Free Workstation Analysis: We analyze your picking process on-site and identify ergonomic risks and efficiency issues.
- Customized solution: Based on the analysis, we recommend the most suitable lifting equipment, tailored to your boxes, your workspace, and your volume.
- Showroom in Drongen: You can test the equipment with your own materials, so you know exactly what you're buying.
- Maintenance Contract: Our service solutions ensure that your material-handling equipment always remains in top condition.
- Training upon installation: Your employees will learn how to use the device correctly and safely right from the start.
Would you like to know which material handling equipment is best suited for your picking process? Contact us for a no-obligation consultation or a free workstation analysis.
