The Challenge: Inefficiencies due to manual unloading methods
Frogg Toggs, a retail store offering outdoor clothing and gear, faced inefficiencies in container unloading due to manual methods. Their full‑spectrum distribution center supports both big‑box retail and direct‑to‑consumer fulfillment. With no associates dedicated solely to container unloading, speed and efficiency are critical—every minute saved gets employees back to their primary roles.
Key challenges:
• Manual unloading using ladders and gravity roller conveyors was slow and inefficient
• Containers required 2–3 hours to unload manually, receiving 1-2 trailers per day
• Container unloading pulls 8-9 associates away from other warehouse priorities
The Solution: Destuff-it™ portable ergonomic conveyor system
The operation implemented the Destuff‑it™ container unloading system, to service four receiving doors. The unit is mobile, allowing it to service all four dock doors.
Key advantages:
• Faster unload times with fewer people
• Flexible deployment across multiple docks
• Proven long‑term ROI and reliability
The Execution: Accelerating unloading without increasing labor demands
One associate operates Destuff‑it ™ inside the container while five to six team members unload along the conveyor line, depending on product mix. The system dramatically accelerates unloading without increasing labor demands.
First evaluated at ProMat and deployed in 2018, Destuff‑it ™ has delivered consistent performance for more than seven years at Frogg Toggs. During a recent facility expansion, the operation reevaluated the market and—after reviewing all alternatives—selected Destuff‑it ™ again, adding a second unit for the new warehouse.
Associates consistently report that the system is safer, easier to use, and more efficient than traditional unloading methods.
The Result: The standard for container unloading
• Unload times cut by up to 50-75% (down to 1–1.5 hours per container)
• Two fewer associates required compared to manual unloading
• Faster return of employees to primary job responsibilities
• High associate satisfaction driven by safety and ease of use
• A clear winner based on performance, cost of ownership, and scalability
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Per Trailer Metrics
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Manual
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Destuff-it™
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Hours Unload
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2 –3
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1 –1.5
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People
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8 –9
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6 –7
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Total Labor Hours
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16 –27
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6 –10.5
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Total Labor Saved
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10–16.5 labor hours per trailer
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Destuff‑it™ continues to be the operation’s standard for container unloading—supporting efficiency today while scaling easily for future growth.