The Challenge: Safety risks of 'laced' tire walls
For one of the world's top three tire manufacturers, efficient distribution is critical. However, at a key European hub, the physical demands of manually handling tires had become a liability. The primary technical challenge lay in the "laced" stacking method, a technique where tires are interlocked to maximize density in high-cube trailers. While efficient for shipping, this creates a dense, unstable "wall" of rubber often reaching 8 feet in height.
To unload these trailers, workers climbed the tire face to over-reach and physically tug interlaced tires free. Conversely, loading required lifting and throwing tires to rebuild this stack. The sheer intensity of exertion, combined with the awkward twisting and stretching required to reach the upper zones of the trailer, presented an unacceptable health and safety risk. The facility needed a solution to eliminate climbing and reduce the biomechanical load on operators without sacrificing cube utilization.
The Solution: Restuff-it™ bi-directional machine
After evaluating various material handling options, the facility implemented the Restuff-it™ Portable Ergonomic Conveyor System. Unlike standard telescopic conveyors, the Restuff-it™ is purpose-built for floor-loaded product. The deciding factor was its integrated, height-adjustable operator platform and bi-directional capability, allowing a single machine to handle both inbound (unloading) and outbound (loading) flows.
The Execution: Optimizing the operator's stance
The implementation transformed the workflow inside the trailer. Instead of standing on the floor, the operator now stands on the Restuff-it™ platform. This platform raises the worker up to 26 inches from the floor, effectively neutralizing the height of the 8-foot tire wall. Operators handle top tiers at chest level rather than above their heads.
Lateral precision is achieved through the pivoting conveyor which moves side-to-side. This enables the worker to access the entire width of the container without dragging heavy tires. During unloading, the operator guides tires from the laced wall directly onto the belt with minimal force. The machine's DC drive system advances it deeper into the trailer autonomously as the wall recedes, maintaining the optimal ergonomic zone.
The Result: Safety, morale, and throughput
The impact was immediate. Replacing the "climb and tug" method with an ergonomic, platform-based process minimized back and muscle strain. Eliminating overhead lifting and climbing reduced the risk of acute injury. The facility also reported an increase in throughput, as the consistent mechanical pace of the conveyor outperformed the stop-and-start nature of manual labor. Employee morale improved as the physical toll of the shift decreased, turning a grueling task into a manageable operation.