Let’s get straight to it: ergonomic injuries aren’t just a “safety” problem. They’re a business problem—one that quietly chips away at your productivity, workforce, and bottom line.
And if you think you can’t afford to invest in automation right now, here’s the real question: Can you afford not to?
The real cost of ignoring ergonomics
Musculoskeletal disorders (MSDs) caused by repetitive tasks like manual palletizing don’t just impact workers—they drain entire operations. We’re talking about:
- $167 billion in total workplace injury costs in the U.S. alone
- Over $2 billion in MSD-related claims in British Columbia from 2019–2023
- An estimated €17.2 billion in production losses from MSDs in Germany
Those numbers are red flags.
Behind every stat is a team slowed down, a line paused, a role left unfilled. Chronic back pain doesn’t just send workers home—it sends costs skyrocketing and schedules into chaos.
The risk isn’t just physical. It’s financial.
Every strain, sprain, or tweak carries a price tag:
🩹 Direct costs
Medical bills, compensation, rehab, insurance premiums
📉 Indirect costs
Lost productivity, missed shipments, temporary labor, morale damage
📈 Reputation risk
Poor safety records hurt your ability to attract and retain talent
Add in the growing global pressure for compliance—from OSHA in the U.S. to EU directives—and ignoring ergonomics quickly becomes a gamble no smart business should take.
“Musculoskeletal disorders (MSDs) injuries do not have only direct medical costs but also hidden indirect costs which can be 1 to 5 times higher than the direct costs. These costs can impact a company’s profitability and may require increased sales to offset the additional costs.” — Carla Silver, Certified Safety Professional and Safety Innovator
Why manual palletizing is the flashing warning light
Manual palletizing sits at the intersection of repetitive motion, awkward posture, heavy lifting, and high frequency. It’s the textbook case of ergonomic risk.
And yet—it’s also the easiest task to automate.
Automation doesn’t just lower your injury rate. It:
- Eliminates the physical hazard entirely
- Reduces claims and insurance costs
- Frees up workers for safer, higher-value roles
- Boosts consistency and throughput
In other words, automation turns a cost center into a performance advantage.
Safer doesn’t mean slower
Some still assume ergonomic improvements slow things down. Not with cobot palletizers. Robotiq’s solutions are designed for:
- Quick deployment (installed in under 3 days)
- Minimal floor space
- Fast, repeatable ROI
That means you can reduce risk and ramp up production—without the trade-offs.
So, can you afford to ignore ergonomics?
When you factor in injury costs, insurance hikes, and labor turnover, doing nothing may be your most expensive option.
Start with one palletizer. See the results. Scale smart.
Your team stays safe. Your business stays strong.
Just how much is manual palletizing costing your business? We can help you find out!
💻 Don’t miss our Ergonomics webinar with Carla Silver – register today!
📘 Download our Ergonomics ebook, also by Carla Silver.
