Reducing Workplace Injuries & Enhancing Safety - Transforming Food & Beverage Operations with Collaborative Robots (Part 3)

Reducing Workplace Injuries & Enhancing Safety

Repetitive motion and heavy lifting in palletizing can lead to workplace injuries, increasing workers’ compensation claims and operational disruptions. Universal Robots collaborative robots eliminate these risks by taking over strenuous tasks, creating a safer work environment. 

How Cobots Improve Workplace Safety 

1. Reduce Ergonomic Strain - Eliminate Repetitive Lifting:

Manual palletizing often requires workers to lift heavy boxes over and over, increasing the risk of back strains, muscle fatigue, and long-term musculoskeletal disorders (MSDs). 

UR Cobots can handle hundreds of these lifts per hour without tiring or getting hurt. 

2. Lower Risk of Accidents:

By centralizing and organizing the palletizing process, there's less clutter on the warehouse floor therefore reducing slip, trip, and fall hazards.

Unlike traditional industrial robots, cobots can work safely around human employees without requiring extensive safety barriers.

Fewer workers moving around with product = fewer chances for accidents

3. Lowers Risk of Human Error:

Tired workers are more prone to mistakes, like misstacking or dropping items—both of which can lead to injury. 

Automated systems follow programmed patterns precisely. 

4. Handles Hazardous or Awkward Loads: 

Sharp-edged boxes, unstable loads, or heavy items can be dangerous for human hands and backs.  

Cobots can safely manipulate difficult or risky products.

Enhanced Safety Measures with Automation:

• Integrated Safety Sensors: 

    Modern robotic palletizers come with safety light curtains, pressure-sensitive mats, and emergency stops      to protect workers. 

    UR cobots are designed with built-in force sensors and safety protocols, allowing them to stop if they            detect a collision

• Collaborative Robot (Cobot) Options:

    Some systems are designed to work WITH humans safely, reducing risk while maintaining flexibility.

    Take a look at some safety functions on the Universal Robot E-series cobots.  

• Consistent Operation = Predictable Environment: 
  When tasks are automated, the workflow becomes more structured, reducing unexpected movements or actions that can cause accidents. 

Bonus Benefits: 

🙌 Improved morale – Employees are spared from the most physically demanding tasks. 
📈 Higher productivity – Machines don’t get tired or injured. 
⚡ Better compliance – Easier to meet OSHA and workplace safety standards. 

Real-Life Example: 

A snack food company previously experienced frequent injuries due to manual lifting in their palletizing operation.

By introducing a UR cobot, they eliminated injury-related downtime, reducing workers' compensation claims by 40% while ensuring a safer, more comfortable work environment.

Case Study: 

The manual workforce at the L'Oréal India Private Limited plant in Pune was facing issues as end-of-the-line operations were being carried out manually. A single worker was lifting 8,500 kilograms per shift, which was revealed during a risk assessment to be a Level 4 ergonomic risk. The deployment of a UR10e model collaborative robot for Automated Palletizing proved to be efficient, while completely eradicating ergonomic risk, and allowing for flexibility in deployment on                                                                                                                   the shop floor for various applications.

In addition to preventing injuries, automating palletizing led to improved compliance with workplace safety regulations. By minimizing ergonomic risks and aligning with labor safety guidelines, the company reduced the likelihood of fines and inspections. As a result, management could focus on business growth instead of addressing workplace safety concerns, further enhancing long-term operational stability.

INTERESTED IN EXPLORING AUTOMATION FOR YOUR END-OF-LINE?

If you are interested in learning more insights on Automated Palletizing and/or specific technologies used, such as Universal Robots collaborative robots or the turnkey Palletizing Solution from Robotiq , The Knotts Company would be happy to assist!   

Our in-house Knotts Automation & Robotic Teams would be happy to set up a no-charge Application Automation Review.  Upon our initial phone call, we will review all projection information, including current process, goals, estimated output now vs. numbers upon implementation, products being used, weight of product, pallet size, stacking height, etc.  We would then arrange an on-site visit to your facility to see your manual labor process in-person, check product material, see current layout, and take measurements to ensure the correct equipment can be suggested (and fit!) as a solution for your needs. 

LEARN MORE HERE:  https://www.knottsco.com/services/palletizing-solutions 

To get started, please reach out to us at The Knotts Company!

LET’S MAKE YOUR END-OF-LINE OPERATIONS A "ZERO ACCIDENT ZONE" & YOUR MANUFACTURING FLOORS A PLACE WHERE YOUR EMPLOYEES FEEL LESS PRESSURE (LITERALLY)! 

ACCIDENTS HURT, SAFETY DOESN'T.