The Challenge: Overwhelmed Dock Operations
Stauffer Glove & Safety manages a logistics operation spanning 300,000 square feet in Red Hill, Pa. The 116-year-old PPE distributor typically handled three incoming tractor-trailer shipments daily under the supervision of Lead Inventory Control Specialist Rommel Gamez. Manual unloading created a significant bottleneck, with each container requiring approximately six hours to fully unload and unpack.
"Super clusters" of inventory further complicated the workflow. These mixed loads contained up to 30 different SKUs packed unsorted into smaller containers. Stauffer's team manually lifted heavy cases, carried them to the warehouse floor, and sorted them onto 10 different pallets simultaneously. When the global pandemic caused a spike in demand for Personal Protective Equipment (PPE), inbound freight operations reached a breaking point. Gamez noted they were "bombarded by containers," creating an urgent need for a solution to handle high volumes and mixed-SKU sorting without exhausting the workforce.
The Solution: Gorbel Destuff-it™ Portable Ergonomic Conveyor
Stauffer's leadership selected the Gorbel Destuff-it™ after reviewing market options. The Destuff-it differs from fixed telescopic conveyors as it operates as a self-contained, mobile unit. An integrated 24V DC battery system powers the machine, allowing it to move independently between dock doors without cabling.
The system brings the worker directly to the product. A hydraulic operator platform with a 550 lb capacity allows a single operator to reach the top of the container wall safely. This positioning removes the need for step stools or overhead reaching, which directly reduces the fatigue caused by Stauffer's mixed-load sorting requirements.
The Execution: Streamlining the "Super Cluster" Sort
Stauffer implemented the equipment in January 2021 after a trial period. The team deployed the Destuff-it unit directly into incoming trailers. The operator stands on the platform and adjusts it vertically to the necessary working height. Instead of lifting and carrying cases to the floor, the operator slides the "super cluster" cases onto the 24-inch wide pivoting belt.
The conveyor transports the product out of the trailer to the dock area. Downstream workers immediately sort the mixed SKUs onto pallets. While the system offers bi-directional capability, Stauffer focused on the unloading features to ensure continuous flow. Sensing mats and bumper guards on the unit maintained safety within the tight trailer confines.
The Result: Double the Speed, Zero the Strain
The new process delivered immediate, measurable improvements. Unloading time per trailer dropped from six hours to three hours, a 50% reduction. Labor efficiency improved as the operation shifted from a multi-person manual carry team to a single operator feeding the line. The system managed the surge in pandemic-related PPE demand and stabilized the supply chain. Gamez reported that the equipment made a disorganized system easier to manage and significantly reduced the physical lifting burden on the team.
Technical FAQs
1. How does the Destuff-it™ handle mixed-SKU loads like Stauffer's "super clusters"? The Destuff-it functions as a flow regulator. By raising the operator to the box wall, they can rapidly slide mixed cases onto the conveyor belt, which has a 165 lb capacity. This consistent flow delivers items to the dock crew at a waist-high ergonomic level, allowing them to sort onto multiple pallets efficiently without the fatigue of carrying boxes out of the trailer.
2. What are the power requirements for the Destuff-it unit? The unit operates on an integrated 24V DC battery system. It is completely cordless and self-propelled. No hardwired power connection is necessary during operation, which allows the unit to drive independently between different dock doors to service multiple trailers per shift.
3. What is the maximum weight capacity for the operator platform? The operator platform is rated for a maximum capacity of 550 lbs (250 kg). This limit allows it to support an operator plus heavy cases or tools safely, ensuring stability even when the platform is raised to its maximum vertical height to reach the top of a high-cube trailer.