“Is it below 20 kilos? Then it’s high-quality to carry.”
That delusion has lived too lengthy on manufacturing unit flooring.
In actuality, the risks of handbook palletizing aren’t nearly how a lot your group 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 an alternative.
What the “20-pound” rule will get flawed
At first look, 20 kilos doesn’t sound like a lot. However carry that very same field 600 occasions a shift? That’s 6 tons of whole weight moved in a day—usually with twisting, reaching, and bending combined in. The pressure builds quick, particularly when the tempo is relentless.
Right here’s what weight-only considering ignores:
- Repetition: Even mild masses, finished ceaselessly, result in muscle fatigue and joint stress.
- Posture: Awkward lifts from under the waist or above the shoulders dramatically improve the possibility of again and shoulder accidents.
- Distance: Lifting packing containers farther from the physique will increase the power required—and the chance.
- Velocity and stress: Palletizing is a time-sensitive process. That stress provides rigidity and danger to each motion.
That’s why ergonomic consultants—and security companies like NIOSH—use extra holistic instruments to guage lifting danger.
What really issues: The actual danger components
Instruments just like the NIOSH Composite Lifting Index (CLI) account for:
- Frequency and period 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 harm.
Spoiler alert: Many handbook palletizing duties hit that threshold quick—even when packing 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 value per again harm
- Weeks of downtime and misplaced output
- Increased turnover, tougher recruiting
- Elevated insurance coverage premiums
And the worst half? These are preventable.
What to do as an alternative: Get rid of the carry, not simply the load
One of the simplest ways to guard your folks (and your margins)? Get them out of the hazard zone fully.
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 an alternative 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. In case you’re nonetheless counting on outdated guidelines of thumb, you would possibly already be risking greater than you notice..
💻 Be a part of our ergonomics webinar with licensed security professional Carla Silver – register at this time!
📘 Want extra particulars and statistics? Obtain our Ergonomics book, additionally by Carla Silver.
