The Challenge: Manual transloading at scale
Averitt, an award-winning freight transportation and supply chain services provider, faced a significant logistical bottleneck at their distribution centers. The company handles between 2,000 to 3,000 containers annually and relied on a manual transloading process for floor-loaded import/export cargo.
This manual approach created three critical issues. Unloading a single trailer was a grueling 12-hour process that tied up dock doors and personnel. The physically demanding nature of lifting and twisting with heavy cartons led to a higher risk of lower back injuries. Consequently, the difficulty of the job negatively impacted associate morale and led to increased turnover rates in a competitive labor market.
The Solution: Destuff-it™ portable ergonomic conveyor system
Ed Smith, VP of Distribution & Fulfillment, sought a solution that would prioritize associate well-being while increasing throughput. The executive team selected the Destuff-it™ Portable Ergonomic Conveyor System by Gorbel.
Unlike standard conveyors, the Destuff-it™ functions as an ergonomic workstation. An integrated operator platform lifts the worker to an optimal height relative to the box wall. This reduces overhead reaching and bending. The choice was strategic. It was not just about moving boxes. It was about "protecting the product and making life better for associates."
The Execution: Integrating ergonomics into the workflow
Implementation began with addressing initial workforce skepticism regarding automation. Leadership clarified that the Destuff-it™ was an assistive tool rather than a replacement for human workers.
As observed in the project video, the machine drives directly into the shipping container. The operator stands on a safe, elevated platform with intuitive controls to transfer cartons onto the pivoting conveyor belt. This setup prevents excessive lifting or twisting. The conveyor feeds product directly to the dock sorting area. A hydraulic height adjustment allows operators to "attack the wall" of boxes from the top down. This maintains a "power zone" for lifting that reduces physical strain. The transition from manual step-stools to this semi-automated platform allowed teams to maintain a consistent pace without the fatigue that typically sets in during the second half of a shift.
The Result: Doubled throughput and zero injuries
The deployment produced immediate metrics. The standard unloading shift compressed from 12 hours (6 AM – 6 PM) to 8 hours (4 AM – 12 PM). Productivity surged as the facility doubled the number of cartons moved per hour. This allowed dock doors to turn over more frequently. Safety data improved as well. Since implementation, the facility reported zero lost-time injuries related to the unloading process. Efficiency gains mean that three employees can now process five containers in the time it previously took two employees to process two.
"It's the best device we've found so far to enhance the lives of our associates... and to overall better manipulate the volumes that come in," noted Ed Smith.