Repetitive lifting of boxes is one of the most common causes of back pain, shoulder injuries, and long-term absenteeism in warehouses and manufacturing environments. Yet the problem is often not addressed until an employee is unable to work. By taking a proactive approach, you can systematically reduce the physical strain of lifting and protect both your employees and the continuity of your business.
In this guide, you’ll go through six concrete steps to reduce repetitive lifting of boxes: from assessing your current workload to maintaining the equipment you use. Each step builds on the previous one, so that by the end, you’ll have created a sustainable and safe work environment.
Identify the lifting load for each workstation
Before you make any changes, you need to know where the problem is most severe. Analyze every workstation where boxes are handled and document the workload as accurately as possible. Without this baseline measurement, it will be impossible to assess later whether your approach is working.
- Record the weight of the boxes being shipped by mail.
- Count the number of lifting tasks per hour and per day for each employee.
- Note the lifting technique: Is the person bending, twisting, or lifting above shoulder height or below knee height?
- Ask employees directly about any complaints or discomfort they experience during or after lifting.
- Use a simple risk score, such as the NIOSH lifting equation or the MAC method, to objectively compare workstations.
After conducting this assessment, you’ll have a clear overview of which work tasks involve the heaviest lifting loads. Rank them from highest to lowest risk. This way, you’ll know exactly where you can make the biggest improvements and where you need to take action first.
Adjust the workstation layout to minimize lifting movements
Many unnecessary lifting motions are not caused by the weight of the boxes themselves, but by poor workstation layout. By optimizing the physical environment, you can significantly reduce the physical strain before you even use a single assistive device. This is the most cost-effective step in the entire process.
- Place the boxes you use most often at working height—between hip and shoulder level—so you don't have to bend over or reach.
- Minimize twisting and walking movements by positioning the supply and removal points for boxes as close as possible to the employee.
- Use retractable shelves, inclined conveyors, or roller conveyors to move boxes horizontally instead of lifting them.
- Limit the height of box stacks so that employees never have to reach above shoulder height.
After making the adjustments, check to see if employees actually have to bend, twist, or reach less. Ask them for feedback during their first few days back at work after the changes. A well-designed workstation forms the foundation of any ergonomic lifting program and makes the assistive devices you choose in the next step even more effective.
Choose the right tool for your box type
Once your workstation has been optimized, the next step is to select the right ergonomic aid. The choice depends on the weight, dimensions, and material of the boxes, as well as how frequently they are handled. There is no one-size-fits-all solution: the aid must be tailored to your specific situation.
For box handling, these are the most commonly used options:
- Vacuum lifters: ideal for smooth, sealed boxes that are moved repeatedly. A vacuum lifter supports the entire weight of the box, allowing the employee to position it precisely without straining their body.
- Mobile lifters: ideal when boxes need to be placed at varying heights, such as when stacking on pallets or stocking tall racks. Browse our selection of mobile lifters for more options.
- Conveyor belts and roller conveyors: drastically reduce the number of times items need to be lifted by moving boxes horizontally without human intervention.
- Ergonomic lifting straps and exoskeletons: provide back support when handling light boxes that are handled frequently, as a supplement to other measures.
Have employees test the tool with the boxes they handle every day before making a final decision. A tool that seems suitable in theory but is too slow or cumbersome in practice won’t be used and won’t solve the problem.
Implement the solution step by step on the job site
Introducing a new lifting solution requires a structured approach. Rushing the implementation leads to resistance among employees and errors in use, which can actually jeopardize safety. Take the time to go through the process thoroughly.
- Start with a pilot phase at a single workstation with the highest lifting load you identified in step one.
- Provide all employees involved with practical instructions on how to use the tool, including safety considerations.
- Appoint a designated contact person to answer questions and monitor usage during the first few weeks.
- After two to four weeks, assess whether the device is being used correctly and consistently.
- Then roll out the solution to the other workstations based on the lessons learned from the pilot phase.
Actively involve employees in the implementation. They know their workstations best and can identify bottlenecks that aren’t visible from the outside. When people feel that their input matters, acceptance of new work methods increases significantly. With a well-executed implementation, you’re ready for the next step: measuring whether the workload has actually decreased.
Verify that the lifting capacity has actually decreased
To measure is to know. Use the baseline measurement from step one as a reference and repeat the analysis after implementation. This is the only way to objectively determine whether the approach is working and where adjustments are needed.
- Repeat the risk assessment (NIOSH or MAC) for the workstations that have been addressed and compare the results with those from the initial assessment.
- Record the number of reports of physical complaints or discomforts during the period following implementation.
- Observe whether employees use the assistive device consistently or whether they still resort to manual lifting.
- Ask employees to complete a short questionnaire about the perceived burden and ease of use of the tool.
If the lifting load has not decreased sufficiently, go back to step three and consider a different or additional assistive device. Sometimes a combination of a modified workstation layout and a vacuum lifter is needed to achieve the desired result. Make adjustments based on data, not on assumptions.
Maintain equipment to ensure ongoing safety
An ergonomic aid that is poorly maintained does not guarantee safety. Vacuum lifters with worn suction cups, lifters with defective locks, or conveyor belts with damaged rollers can create new risks. Structural maintenance is therefore not a minor issue, but an essential part of your ergonomics policy.
- Develop a maintenance schedule for each piece of equipment based on its frequency of use and the manufacturer's recommendations.
- Have employees perform a visual inspection every day before use: check suction cups, cables, locks, and moving parts.
- Record defects and repairs in a log so that recurring problems can be quickly identified.
- Schedule annual professional inspections by a certified technician.
Proper maintenance extends the lifespan of your assistive devices and ensures safety. Be sure to check out the service and maintenance options available to keep your assistive devices in top condition. A defective assistive device that isn’t being used is just as dangerous as not having one at all: employees will then automatically resort to manual lifting.
How Logitrans Handling Helps Reduce Repetitive Lifting
At Logitrans Handling, we combine technical expertise with in-depth knowledge of ergonomic work practices in warehouses and production environments. We guide companies from the initial analysis through to the full implementation of a customized solution.
- Free workplace analysis: Our specialists will visit your site to assess lifting loads and identify specific areas for improvement.
- Wide range of products: from vacuum lifters and mobile lifters to transport solutions for boxes, bags, sheets, and pallets. View our complete product lineup for an overview.
- Demo space in Drongen: Test the solution with your own boxes before you decide, so you can be sure the system is right for your situation.
- Training during installation: We ensure that employees use the equipment correctly and safely from day one.
- Maintenance Contracts: for preventive and proactive maintenance to ensure your medical devices are always in top condition.
Would you like to know which approach is best suited to your workstations? Contact our team for a no-obligation consultation and discover how we can systematically reduce the lifting load in your company.
