BGS Technic, a long-established family-run manufacturer of automotive hand tools, recently reassessed how physically demanding tasks were handled in its warehouse. The company has always prioritised employee well-being and had already introduced preventive health initiatives such as desk-based exercises and back-training programs. Still, one issue remained: the daily strain caused by moving heavy cartons.

Repetitive lifting of heavy boxes causing fatigue and injuries

Managing more than 10,000 products means the BGS warehouse team must lift a large number of boxes every day. Most parcels weigh up to 40 kg (88 lbs), with some exceeding 100 kg (220 lbs). Before new equipment was introduced, nearly all of this work was done manually, resulting in frequent exhaustion, physical stress, and occasional injuries.

Warehouse Manager Torsten Wirth recognised that even with existing wellness efforts, the warehouse needed further ergonomic improvements. With roughly 2,400 boxes moving through the facility each day, the risk of burnout was high, and the physical demands were making recruitment increasingly difficult. A more sustainable approach was needed to support employees and attract new staff.

Ergonomic lifting equipment for container unloading and box handling

To reduce the physical load on employees while maintaining output, BGS Technic consulted with TAWI and implemented two key technologies:

• A TAWI Container Unloader for handling goods inside shipping containers
• Two high-frequency vacuum lifters mounted on a ceiling rail system for efficient palletising and sorting

The Container Unloader provided the flexibility required at loading bays, allowing staff to drive the unit directly into the container. This eliminated the need for workers to manually manoeuvre heavy cartons in tight spaces. The overhead rail system then supported smooth handling of goods downstream.

These tools were specifically selected to manage loads up to 40 kg (88 lbs), which accounts for around 80% of BGS Technic’s daily box movements. While very heavy items above 100 kg (220 lbs) still posed challenges, the equipment dramatically reduced the strain experienced in the vast majority of tasks.

“Today’s process is easier after the introduction of the TAWI lifting aids, and the work is significantly less physically demanding for the employees. Sick leave due to manual handling has been reduced.”
— Torsten Wirth, Warehouse Manager, BGS Technic

A healthier work environment and easier recruitment

The impact of the lifting systems was immediate. Employees no longer needed to lift heavy boxes manually, reducing injury risk and lowering absenteeism. The change also made the warehouse environment more appealing to new hires. Tasks that once discouraged applicants were now far more approachable thanks to the mechanical support.

"What we have noticed is that new employees are not deterred because the container unloader makes the work much easier and the motivation is completely different right from the start”
— Jose Rousseau, Site Manager, BGS Technic

A safer, more efficient workflow

By integrating TAWI’s ergonomic lifting solutions, BGS Technic successfully created a warehouse environment that protects employee health while maintaining productivity. Staff can now manage the same workload without the physical toll that previously accompanied daily operations.

Ready to speak to our Logistics experts and scope out smart lifting solutions for your distribution centre? Get in contact with TAWI. https://www.tawi.com/industries/logistics