The Challenge: The floor-loading bottleneck
A prominent last-mile delivery business faced a major operational hurdle due to the rapid evolution of the e-commerce industry. As retail demands shifted, the facility saw a dramatic increase in loose-loaded trailers. This meant unpalletized cargo required manual handling for every single box.
This "floor load" method created significant inefficiencies. The manual process required a three-person team to physically lift and carry inventory, often from the floor to a conveyor. This workflow was slow. It took approximately 2.5 hours per trailer. It was also hazardous. Handlers faced high risks of musculoskeletal injury from repetitive bending and reaching. Loose-stacked boxes were prone to falling and endangering staff. Management faced a difficult choice. They needed to increase throughput to meet e-commerce demand without increasing headcount or compromising worker safety.
The Solution: Destuff-it™ portable ergonomic conveyor
The Distribution Center General Manager identified the Destuff-it™ Portable Ergonomic Conveyor as the right solution to connect manual labor and automation.
Unlike standard extendable conveyors, the Destuff-it™ features an integrated hydraulic platform. This raises the operator to the best working height. This "power zone" positioning ensures that whether a worker handles boxes at the floor or the ceiling of the container, the transfer to the belt is ergonomic. They chose the system for speed, but also to aid workforce retention by reducing physical strain.
The Execution: Seamless integration and adoption
The implementation revealed the intuitive design of the system. Despite initial skepticism that automation might "displace" jobs, the floor team’s reaction was overwhelmingly positive. Management described it as "like Christmas."
Rapid training The learning curve proved negligible. New operators could be trained and fully operational within minutes, regardless of language barriers or previous experience.
Ergonomic advantage The platform raises up to 26 inches. This allows operators to glide boxes onto the belt rather than lifting them overhead or bending to the floor. This feature removed the physical strain of handling heavy or high-stacked loose loads.
Workflow optimization The machine reduced the required team size from three handlers to two. This freed up the third employee for other tasks within the warehouse.
The Result: ROI in record time
The impact on the facility’s bottom line was immediate. By deploying the Destuff-it™, the company achieved specific results:
- Reduced unload time: Trailer turn times dropped from 2.5 hours to 1.5 hours. This was a 40% efficiency gain.
- Labor optimization: The standard crew size dropped by 33% (from 3 to 2 operators) while increasing speed.
- Safety wins: The stable platform and ergonomic height adjustment lowered the risk of falling packages and handler fatigue.
- Financial success: The initial unit paid for itself in just six months based on labor savings and increased throughput. This prompted the immediate purchase of a second unit.