The Challenge:
At a 104,000‑square‑meter distribution center in Poland, handling Home and Garden products, container unloading was slow, labor‑intensive, and physically demanding. Loose goods made up the majority of inbound shipments, and product variety added complexity to every load.
Key challenges included:
• Manual unloading requires three to four workers per container
• Heavy packages—up to 70 kg—creating physical strain and safety risks
• Four‑hour unload times that strained labor resources and delivery windows along their 68 unloading docks
• High SKU count trailers, ranging from six products types to fifty per container
The Solution: Destuff-it™ portable ergonomic conveyor system
The operation deployed the Destuff‑it™ container unloading system to replace manual unloading with a safer, high‑throughput process designed for loose, mixed freight.
Core advantages:
• Conveyor‑assisted unloading that eliminates the stress of heavy lifting
• A fully articulating front pivoting conveyor for precise package handling
• A stable unloading platform that improves safety and control
• An easy to learn system for new operators
The Execution:
With the front pivoting conveyor positioned directly beneath the load, operators slide packages onto the belt instead of lifting them. Goods are removed from the top down, preventing shifting and falling throughout the process. The conveyor’s vertical and horizontal flexibility allows fast, ergonomic movement inside the container.
Employees rotate roles for a more varied workday and reduced exposure to extreme temperatures. Training was quick and intuitive, and the system requires minimal maintenance with responsive local support.
The Result:
• 80–120% increase in unloading efficiency, depending on product mix
• Four containers unloaded in five hours—up from one container in four hours
• Six to seven containers processed per shift
• Significantly reduced physical strain, especially on the lower back
• Fewer accident‑related incidents during unloading
• Consistent compliance with four‑hour unloading windows
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Metric
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Before
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After (with Destuff‑it™)
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Workers per container
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3–4 workers
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3–4 workers
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Unloading time per container
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4 hours
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~1 hour 15 mins
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Containers processed per shift
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~2 containers
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6–7 containers
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Physical strain / safety
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Heavy lifting up to 70 kg; highsafety and lowe back risk
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Significantly reduced physical strain; fewer accident‑related incidents
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4‑hour unloading window compliance
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Strained labor resources and delivery windows
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Consistent compliance
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With plans to add a second Destuff‑it™ unit and integrate automated pallet wrapping, the operation is positioned to further increase throughput and streamline material flow into storage.