“Is it underneath 20 kilos? Then it’s tremendous to raise.”
That fantasy has lived too lengthy on manufacturing unit flooring.
In actuality, the risks of guide palletizing aren’t nearly how a lot your workforce lifts—however how usually, how far, and the way awkwardly. The so-called “20-pound rule” overlooks the cumulative toll of repetitive movement, poor posture, and continuous shifts. And for meals and beverage producers, that may imply rising harm dangers hiding in plain sight.
Let’s unpack why weight alone is a deceptive metric—and what to deal with as a substitute.
What the “20-pound” rule will get flawed
At first look, 20 kilos doesn’t sound like a lot. However raise that very same field 600 instances a shift? That’s 6 tons of complete weight moved in a day—usually with twisting, reaching, and bending blended in. The pressure builds quick, particularly when the tempo is relentless.
Right here’s what weight-only pondering ignores:
- Repetition: Even gentle masses, performed ceaselessly, result in muscle fatigue and joint stress.
- Posture: Awkward lifts from under the waist or above the shoulders dramatically improve the prospect of again and shoulder accidents.
- Distance: Lifting containers farther from the physique will increase the power required—and the danger.
- Velocity and strain: Palletizing is a time-sensitive job. That strain provides rigidity and danger to each motion.
That’s why ergonomic specialists—and security companies like NIOSH—use extra holistic instruments to guage lifting danger.
What truly issues: The actual danger elements
Instruments just like the NIOSH Composite Lifting Index (CLI) account for:
- Frequency and length of lifts
- Vertical and horizontal attain distances
- Twisting and asymmetry
- Coupling (grip high quality)
- Load weight and dealing with zone
A CLI rating above 1.0 means elevated danger. Over 3.0? You’re doubtless on borrowed time earlier than somebody will get damage.
Spoiler alert: Many guide palletizing duties hit that threshold quick—even when containers weigh lower than 20 kilos.
The price of ignoring ergonomic actuality
Harm from overexertion isn’t simply painful. It’s costly:
- $39,000+ common price per again harm
- Weeks of downtime and misplaced output
- Larger turnover, tougher recruiting
- Elevated insurance coverage premiums
And the worst half? These are preventable.
What to do as a substitute: Remove the raise, not simply the load
One of the simplest ways to guard your individuals (and your margins)? Get them out of the hazard zone solely.
Robotic palletizing with a Robotiq cobot system means:
- No extra repetitive lifting
- No extra awkward postures
- A CLI rating of zero
- And a system that installs in simply 3 days, with no facility redesign
In different phrases: Much less danger, extra reliability—and a workforce that may deal with higher-value work as a substitute of repetitive pressure.
Backside Line: Do not let a quantity idiot you
That 20-pound field might sound innocent. However the fact is, weight is only one piece of the puzzle. When you’re nonetheless counting on outdated guidelines of thumb, you may already be risking greater than you understand..
💻 Be a part of our ergonomics webinar with licensed security professional Carla Silver – register as we speak!
📘 Want extra particulars and statistics? Obtain our Ergonomics book, additionally by Carla Silver.
