Yes, an ergonomic lifting solution works even at a high picking pace, but only if it is specifically tailored to the speed and type of movement involved in that process. The choice of equipment, the controls, and its integration into the workstation determine whether ergonomic lifting supports or hinders productivity. Below, we answer the most frequently asked questions about lifting equipment and picking pace.
What slows down a lifting solution when the picking rate is high?
A lifting solution slows down the picking process when the machine’s cycle time is longer than the desired picking frequency. In practical terms, this means that if an employee can lift faster than the machine can respond, the machine becomes a bottleneck rather than a tool. The main causes are slow suction, too many operations per cycle, and poor positioning of the device.
Other factors that can slow down a lifting solution include:
- Long activation time: Devices that take several seconds to build a vacuum or grasp a load are not suitable for a high-speed picking cycle.
- Complex operation: If an employee needs to press multiple buttons or perform multiple steps for each pick, the time savings are quickly lost.
- Insufficient range or freedom of movement: A device that does not move smoothly with the operator slows down every individual action.
- Wrong suction cup or gripper: A suction surface that doesn't fit properly on a box or bag results in repeated attempts and wasted time.
An ergonomic lifting solution that isn't tailored to the picking process for boxes or other products can therefore do more harm than good. That's why a workstation analysis beforehand is crucial.
Which lifting solutions are suitable for heavy-duty use?
For intensive use and a high picking rate, equipment that responds quickly, is easy to operate, and is mechanically reliable under constant load is ideal. Vacuum lifters with rapid suction, balancers, and semi-automatic systems perform best in environments where hundreds of picks are made per shift.
The most common categories for intensive use are:
- Vacuum lifters: Ideal for flat, non-porous surfaces such as boxes, sheets, and plastic packaging. They lift quickly and release on command.
- Balancers: Suitable for repetitive movements in which the operator supports the weight but does not feel it. They follow the worker's movements without delay.
- Semi-automatic lifting solutions: For applications where the movement of pallets or heavy loads can be automated, allowing the operator to focus on the picking process itself.
Browse our full range of material handling products to get an idea of which equipment is suitable for your specific situation.
How fast is a vacuum lifter in a picking process?
A modern vacuum lifter can pick up and release a load in one to two seconds per cycle, making it suitable for a high picking rate. The effective speed depends on the type of suction cup, the surface texture of the product, and the settings of the vacuum system. With properly configured systems, the cycle time is barely noticeable to the operator.
In practice, there are two factors that determine the speed of a vacuum lifter in a picking process:
- Suction speed: The faster the vacuum builds up, the less time the operator has to wait before moving the load. High-quality systems reach the required vacuum level in less than a second.
- Unloading speed: Unloading the load must be just as fast as picking it up. Systems with direct valve venting are the fastest in this regard.
For applications such as bag handling or moving sheets, a vacuum lifter is often the fastest ergonomic solution, which also significantly reduces physical strain.
What is the difference between a balancer and a vacuum lifter when it comes to high-speed picking?
The main difference is the way the load is held. A balancer compensates for the weight of a load held by the operator, while a vacuum lifter holds the load independently using negative pressure. In high-speed picking, this means that a balancer responds more quickly to the operator’s movements, but the worker must grasp and release the load themselves.
When should you choose a balancer?
A balancer is most suitable when products are irregularly shaped, porous, or when the gripping motion is too variable for a standard suction cup. The operator has complete control over the pace, which can be an advantage at very high picking frequencies. The disadvantage is that the worker physically holds the load, which can be tiring for the hands and wrists with repeated use.
When should you choose a vacuum lifter?
A vacuum lifter is the better choice when products have a smooth, even surface, such as boxes, sheets, or plastic packaging. The operator does not have to physically hold the load, which significantly reduces fatigue during high-volume picking. The device supports the entire weight, allowing the employee to focus on positioning and speed.
When is a semi-automatic lifting solution a good investment?
A semi-automatic lifting solution is worthwhile when a task is performed so frequently that even an ergonomic hand-held device remains a bottleneck, or when the combination of lifting weight and picking frequency is too high for safe manual work. In practice, this is the case when there are more than three hundred picks per shift with loads exceeding fifteen kilograms, or when an entire pallet task can be automated.
Specific situations in which semi-automation is the right choice:
- Repeatedly moving pallets, with the operator only steering and no longer lifting them
- Picking processes in which products are always picked from the same location and placed in the same location
- Environments with high employee turnover or a large number of temporary staff, where ease of use is essential
- Situations in which ergonomic complaints are already present and the workload cannot be reduced
Semi-automation is not a replacement for employees, but a way to take over the most physically demanding tasks. Take a look at real-world examples to get a concrete idea of how this is applied in industrial settings.
How Logitrans Handling Helps Ensure Ergonomic Lifting at a High Picking Pace
We understand that an ergonomic lifting solution in a high-volume picking operation must meet different requirements than one in a standard warehouse environment. Speed, reliability, and ease of use are just as important as the ergonomic benefits. That is why we approach every request with a thorough analysis of the workstation and the picking process.
What we offer specifically:
- Free Workstation Analysis: We assess the picking frequency, the product, the weight, and the movements before proposing a solution.
- A wide range of lifting equipment: From vacuum lifters and balancers to semi-automatic systems, tailored to your picking rhythm and warehouse layout.
- Demonstration Room in Drongen: You can test the solution with your own products before making a decision, so you can be sure you’re making the right choice.
- Training and Maintenance: We ensure proper commissioning and offer maintenance contracts so that your equipment always performs at its best.
- Semi-automation solutions: For processes where manual lifting is no longer an option, even at high picking frequencies.
Are you curious about which ergonomic lifting solution is right for your picking process? Contact us for a no-obligation consultation or a customized workstation analysis.
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