Heavy manual lifting is a common challenge in manufacturing environments.

When employees are repeatedly required to lift, move, inspect and reposition heavy materials, the result can be increased fatigue, ergonomic risk and reduced productivity.

For one chemical manufacturer, employees were manually handling 60-pound bags as part of an inspection and repacking process. The repetitive nature of the work required multiple operators and created an opportunity to improve both workplace ergonomics and material-handling efficiency.

Air Power Manufacturing Solutions helped address the challenge with a customized vacuum lifting system that combined Schmalz vacuum lifting technology with Gorbel jib cranes and Presto lift/turntables.

The result was a safer, more ergonomic and more efficient material-handling process.

The Material Handling Challenge

The manufacturer’s process required employees to remove 60-pound bags from one pallet, inspect the bags, and then place them onto another pallet.

Because of the weight and repetitive nature of the application, the process required five to six operators who rotated between lifting, inspecting and repacking the bags.

Employees were repeatedly exposed to:

• Manual lifting of 60-pound bags
• Bending and reaching
• Repetitive lifting and repositioning
• Employee fatigue
• Potential ergonomic risks
• Inefficient material movement

The manufacturer needed a solution that could reduce the physical demands placed on employees without slowing down production.

A Customized Vacuum Lifting Solution

Air Power evaluated the application and developed a customized ergonomic material-handling system designed around the manufacturer’s existing workflow.

The solution incorporated three primary technologies:

Schmalz Vacuum Lifting Equipment

A Schmalz vacuum lifter became the centerpiece of the system.

Vacuum lifting technology allows operators to pick up and move heavy bags using vacuum power rather than relying on traditional manual lifting.

The one-handed vacuum lifter provided operators with greater control while significantly reducing the physical effort required to move each bag.

Instead of repeatedly bending down and manually lifting 60-pound bags, employees could use the vacuum lifting device to pick up, transport and position the bags more efficiently.

Gorbel Jib Cranes

The vacuum lifting equipment was paired with Gorbel jib cranes to provide the necessary range of motion.

The jib cranes allowed operators to move the vacuum lifter between the required pallet positions while maintaining an efficient workstation layout.

This helped eliminate unnecessary carrying and repositioning while keeping the lifting equipment readily accessible to the operator.

Presto P3 Spring Lift/Turntables

Presto P3 spring lift/turntables were also incorporated into the material-handling system.

The turntables allow materials to be rotated and positioned for easier access.

Instead of employees reaching across a pallet or repeatedly walking around it to retrieve materials, the turntable helps bring the product into a more accessible position.

This small change can make a significant difference when employees perform the same handling operation hundreds of times during a work shift.

The Results: Fewer Operators and Greater Efficiency

The new vacuum material-handling system delivered significant improvements to the manufacturer’s operation.

A process that previously required five to six operators could now be performed by just two operators.

The system also reduced the amount of manual lifting required from employees, helping create a more ergonomic working environment.

Key benefits included:

• Reduced manual lifting
• Less employee fatigue
• Improved workplace ergonomics
• Reduced physical demands on operators
• Improved material flow
• Fewer employees required for the application
• Improved takt time
• More efficient inspection and repacking
• A more consistent material-handling process

The application demonstrated that an investment in ergonomic lifting equipment can deliver benefits that extend well beyond employee comfort.

When material handling becomes easier and more efficient, manufacturers can improve both employee safety and operational performance.

Why Vacuum Lifters Are Valuable in Manufacturing

Vacuum lifting systems can be an effective solution for manufacturers that routinely move bags, boxes, sheets, panels, containers and other materials.

Unlike traditional lifting methods, a vacuum lifter can allow an operator to move heavy or awkward materials with substantially less physical effort.

Depending on the application, vacuum lifting equipment can help manufacturers address challenges involving:

Heavy materials: Reduce the physical effort required to move repetitive loads.

Repetitive lifting: Make high-frequency material movement easier on employees.

Awkward loads: Improve control when handling materials that are difficult to grip or position manually.

Ergonomic risks: Reduce bending, reaching, twisting and manual lifting.

Labor utilization: Allow fewer employees to perform certain material-handling tasks.

Production efficiency: Improve the flow and speed of repetitive material movement.

Designing Material Handling Around the Operator

One of the most important considerations when implementing an ergonomic lifting solution is the operator.

The best material-handling systems don’t simply move the product. They make the entire process easier for the person performing the work.

That means evaluating factors such as:

• Material weight
• Material dimensions
• Load shape and surface characteristics
• Lifting frequency
• Pick-and-place locations
• Required lifting height
• Horizontal travel distance
• Available floor space
• Operator reach
• Existing production processes

By looking at the complete application, manufacturers can develop a material-handling solution that improves both ergonomics and productivity.

Air Power Manufacturing Solutions: Your Material Handling Partner

At Air Power Manufacturing Solutions, we help manufacturers identify opportunities to improve the way materials are moved, positioned and handled throughout their facilities.

Our material-handling capabilities include:

• Vacuum lifting systems
• Vacuum lifters
• Jib cranes
• Lift assists
• Ergonomic lifting equipment
• Material positioning equipment
• Turntables
• Overhead rail systems
• Custom material-handling solutions

We work with leading manufacturers and equipment providers to develop solutions based on the specific requirements of each application.

Whether you’re trying to eliminate repetitive manual lifting, improve employee ergonomics, reduce labor requirements or increase production efficiency, the right industrial material-handling system can make a measurable difference.

Is Your Manufacturing Process a Candidate for Vacuum Lifting?

If your employees routinely lift heavy bags, boxes, containers, panels or other materials by hand, it may be time to look at an ergonomic alternative.

A vacuum lifting system could help your operation reduce manual handling, improve ergonomics and increase productivity—just as it did for this chemical manufacturer.

Let Air Power Manufacturing Solutions evaluate your application and help identify the right material-handling solution for your operation.

Ready to Improve Your Material Handling?

Contact Air Power Manufacturing Solutions today to discuss your application and learn how vacuum lifting and ergonomic material-handling technology can help your manufacturing operation.

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