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Building an Ergonomic Packing Station for Warehouse Optimization


A more efficient packing station means a more efficient warehouse — and to maximize your operation, you’ll need to prioritize ergonomics.

Building an Ergonomic Packing Station for Warehouse Optimization

Even in highly automated warehouses, most packing is still performed by humans. And if the packing station isn’t designed for each worker’s reach zone, work height, and comfort, you can expect some issues: lower throughput, incorrect shipments, higher turnover rates, and on-the-job injuries from repetitive motions (not to mention the worker’s compensation claims associated with those injuries). 

By understanding some basic design principles — and investing in ergonomically designed material handling equipment (MHE) — you can build packing stations that work for every worker. In this article, we’ll discuss those principles and help you outfit your facility.

Packing Station Ergonomics: Understanding the Costs

According to a report from the U.S. Government Accountability Office (GAO), warehouse package and delivery workers had the highest estimated rate of serious injury among private sector industries. The most common category of injuries: overexertion, including “injuries and illnesses resulting from activities like excessive physical efforts, repetitive motion, and awkward or unnatural postures.”

Those injuries are expensive:

  • In 2018 alone, non-fatal injuries within the transportation and warehousing industry incurred costs of approximately $84.04 million per week, per the National Safety Council.
  • That’s an average annual expense of $240,000 per warehouse.
  • The average cost per medically consulted injury in 2018 was $41,000.

Unfortunately, injury rates seem to be getting worse within the warehousing industry — but that’s a reversible trend. Effective warehouse packing stations can support ergonomic worker positioning, enhancing employee productivity and addressing a key bottleneck.

Ergonomic Hazards in Warehouse Packing Stations

The warehousing industry has high injury rates for a simple reason: Many essential tasks are physically demanding. Without good ergonomics, injuries are inevitable.

That’s particularly true in packing areas. Common hazards include:

  • Overexertion from Lifting: Handling packages, particularly those exceeding recommended weight limits (roughly 35 pounds, per OSHA and NIOSH), places excessive strain on the back and shoulders.
  • Repetitive Motions: Tasks performed repeatedly throughout a shift — scanning barcodes, applying tape, folding boxes, or handling small items using pinch grips — can lead to musculoskeletal disorders (MSDs) affecting the hands, wrists, arms, and shoulders.
  • Awkward Postures: Reaching excessively for supplies stored too far away, bending frequently due to non-adjustable work surface heights, or twisting the torso while handling materials forces the body into unnatural positions.
  • Prolonged Static Positions: Standing (or sometimes sitting) in one position for extended periods without adequate support, such as anti-fatigue matting or properly adjusted seating, can lead to fatigue, discomfort, and circulatory issues in the legs and back.
  • Forceful Exertions: Applying significant force (manually pulling stretch wrap or maneuvering very heavy or cumbersome items without mechanical assistance) can directly lead to muscle strains.

It’s worth noting that many individual movements might seem like minor concerns to both the employee and the employer. But no repetitive or awkward movement is a non-concern — over days, weeks, and months, they have a cumulative effect.

Remember, by definition, non-ergonomic motions are not efficient. They cost you money, even if there’s never an injury! To optimize your warehouse, you need to eliminate ergonomic hazards wherever possible.

Performing a Workflow Analysis for Packing Station

Optimizing your packing station starts with a workflow analysis. 
In this process, you’ll map every step — from item arrival to final sealing — to eliminate wasted motion. The goal is to design a layout that minimizes physical strain while maximizing throughput.

First, determine how items arrive at the station. Do they travel via conveyor (which means you’ll need seamless integration) or are they delivered manually (which requires dedicated staging space)?

Next, ensure a logical flow for materials, typically moving from storage towards shipping. If storage is left and shipping is right, you’ll need to orient tasks accordingly. Use clear signage to maintain this flow, reduce errors, and ensure consistency across shifts.

Your analysis should allocate space for the essential zones within each packing station:

  • Staging/Quality Control: For incoming items and order verification.
  • Packing/Labeling: The primary work surface with easy access to necessary tools.
  • Supply Storage: Organized areas for boxes, tape, filler, etc., within ergonomic reach.
  • Waste/Recycling: Conveniently located bins. Note that emptying bins can also introduce ergonomic risks, so consider Bin Dumpers for handling waste & recycling. Learn how Bin Dumpers simplify material handling in the workplace.
  • Outgoing: A clear area or interface for transferring packages to shipping.

By minimizing unnecessary travel and optimizing the layout for the actual tasks performed, you directly support ergonomic principles and boost packing efficiency.

Key Ergonomic Considerations for Packing Station Design

Once your workflow is mapped, focus on integrating specific ergonomic features into the packing station design. A good packing station should feature: 

1. Adjustable Work Height

Implement adjustable height tables or work surfaces to keep materials within the order packer’s ergonomic power zone. 

The power zone refers to the area of the body where manual tasks, particularly lifting, can be performed with the least amount of physical stress and the lowest risk of injury. This zone is generally located:   

  • Vertically: Between mid-thigh and mid-chest height.   
  • Horizontally: Close to the front of the body.

Working within this zone allows individuals to utilize their strongest muscles (legs and core) most effectively while minimizing strain on more vulnerable areas like the lower back and shoulders. 

When you lift or handle items inside this power zone, your body is in a more neutral and stable posture, reducing the force required and the likelihood of awkward movements. You may need to adjust a packing or shipping station setup between shifts to accommodate different workers — height-adjustable tables make this possible.

Product to Consider: Adjustable Packing Desks

Solus Group carries Adjustable Packing Desks (APD) from BHS, which can be manually adjusted to keep workers comfortable. The APD is available with 3" back and side lips to prevent items from falling off, and the heavy-duty steel construction supports heavier products (and multiple order packers per station).

2 . Appropriate Reach Zones

Design the station layout so frequently used tools and materials are within the worker’s primary reach zone (close to the body, requiring minimal leaning or stretching). This minimizes awkward stretching and twisting. 

Utilize workbench uprights, adjustable shelving (potentially tilted), and accessory rails to keep essential items like tape dispensers, scanners, and common box sizes easily accessible.

3. Comfortable Seating

If packing tasks involve sitting, high-quality industrial task chairs are a must. Look for features like adjustable seat height, proper lumbar (back) support, and potentially seat angle adjustment. 

While armrests can be beneficial, ensure they don't impede necessary lateral movement. For standing-dominant tasks, provide anti-fatigue mats to reduce leg and back strain. 

The best practice is to look for chairs specifically built for multi-shift use — and if possible, you should give employees the option to sit or stand. Provide anti-fatigue mats for stations that will require prolonged standing. Anti-fatigue mats have a degree of cushioning, and they’re not an expensive addition as a packing station solution (particularly when compared with the cost of a worker’s comp claim).

4. Easy Access to Tools and Materials

All essential tools must be within easy reach to eliminate searching and awkward movements. This includes:

  • Packing Paper/Filler: Position dispensers (vertical, horizontal, or integrated systems) for easy access without poor posture.
  • Tape: Use ergonomic dispensers (e.g., grooved/foam handles, water-activated) placed strategically.
    Parcels: Handle items at adjustable heights. Utilize Lift Tables, conveyors, or Tilt Tables for heavy or bulky parcels to minimize manual lifting risks.
  • Scanners: Opt for lightweight, well-balanced scanners. Consider wearable scanners for hands-free operation or strategically place stationary scanners to avoid neck strain.

5. Organized Storage

Provide sufficient, well-organized storage for all packing supplies (boxes, labels, void fill packaging products, and so on) and waste/recycling. Use adjustable shelving, bins, and potentially under-surface storage with pull-out trays.  

An efficient packing station layout is safer and allows for more ergonomic movement, so the placement of items should be consistent and intuitive. Keep low-use items, accessible but out of the immediate primary work zone.

6. Proper Lighting

Ensure adequate illumination across the entire workstation. A combination of overhead ambient lighting, focused task lighting, and potentially under-shelf lighting improves visibility, reduces eye strain and headaches, and helps minimize errors during packing and labeling.

Related: Light Fixture Installation Tips for Construction Electricians

7. Hazard-Reducing Material Handling Equipment (MHE)

Integrate appropriate MHE to minimize manual lifting, carrying, and forceful exertions. We mentioned these earlier when discussing easy access to materials, but Solus Group carries a wide range of equipment to handle the most demanding packing tasks.

Specific options include:

  • Mobile Lift Tables, available in Manual, Powered, and Self-Leveling options (MMLT, PMLT, SMLT, respectively), offer the flexibility to move work materials within or between modular packing stations, with powered and self-leveling versions maintaining ergonomic heights automatically to reduce bending and lifting.
  • Scissor Lift Tables (LT Series), including the Dual Scissor Lift Table (LTD Series) models, are ideal for handling heavier packages or accessing materials stored at various heights near the packing station. They provide ergonomic positioning for items up to 10,000 lbs.
  • Pallet Carousels (PCSP-S, PCSP-P) improve efficiency when packing directly from or onto pallets near the station by allowing easy rotation and convenient access to goods. Available with Spring Loaded and Pneumatic Airbag models.
  • Powered Mobile Lift & Tilt Tables (PMLTT) provides a flexible work positioning solution that combines lifting with tilting capabilities, helping prevent musculoskeletal injuries by bringing container contents within easy reach.
  • The Powered Mobile Skid Tilter (PMST) is specifically designed to tilt skids, preventing worker strain and fatigue by positioning loads ergonomically for easy access during packing.
  • The Ground Level Tilt Table (GTT) provides improved productivity in the order packing process by tilting containers directly from the floor level for better access to contents.
  • The Mobile Gaylord Dumper (GLD) offers a specialized solution for efficiently and ergonomically handling and dumping contents from large Gaylord containers often used in bulk packing operations.
  • An Upender (UPD) is useful in packing stations that handle heavy or unwieldy items requiring controlled 90-degree repositioning before packing.
  • Conveyors: Generally, this refers to conveyor belts or gravity rollers integrated into a custom packing station; Solus Group also carries Vertical Reciprocating Conveyors (VRC), a type of material handling infrastructure that moves loads between levels.

Strategically using MHE significantly reduces the risk of overexertion injuries, which are among the most common and costly in warehouse environments.

Optimize Your Warehouse Workflow with Solus Group

Finding the perfect MHE solution requires matching equipment capabilities to your specific packing tasks and layout. At Solus Group, we specialize in helping facilities identify and implement MHE that integrates flawlessly into their existing workflows. 

Ready to build packing stations optimized for performance and ergonomics? Contact the material handling experts at Solus Group today by calling 314-696-0200.


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