Körber ErgoUnload Parcel Unloading System

Project Overview

Körber has developed the ErgoUnload system to address one of the major pain points in parcel logistics operations - the unloading of loose-loaded trailers and swap bodies. This innovative solution tackles the significant challenges associated with manual unloading processes that have traditionally required substantial physical effort and limited throughput in logistics facilities.

The system is designed to transform the unloading area from a bottleneck into an efficient, ergonomic operation that supports downstream processes. By focusing on both human factors and operational efficiency, ErgoUnload represents a holistic approach to improving parcel logistics workflows.

The solution specifically targets the unloading phase where loose-loaded parcels create particular challenges for operators, requiring repetitive lifting and handling that can lead to fatigue, injury, and reduced productivity.

Technical Solution

ErgoUnload System Design

The ErgoUnload system provides an ergonomic and efficient solution for unloading loose-loaded trailers. The system is designed to work in conjunction with telescopic conveyors, creating an integrated unloading station that optimizes both human factors and material flow efficiency.

Key Features

The system enables throughput of up to 3,000 parcels per hour with just one operator, representing a significant efficiency improvement over traditional manual unloading methods that typically achieve much lower rates.

Physical force requirements are reduced from the current 50-100% range to approximately 10%, dramatically decreasing the ergonomic strain on operators and creating a safer, more sustainable working environment.

The integrated design with telescopic conveyors doubles throughput per dock, maximizing the productivity of existing dock infrastructure while minimizing space requirements.

Results & Benefits

The system achieves an impressive 3,000 parcels per hour unloading capacity, enabling faster trailer turnaround and supporting higher overall facility throughput for downstream processes.

The 90% reduction in required physical force leads to higher staff acceptance of the unloading process, reducing turnover and improving operator satisfaction in what has traditionally been one of the most physically demanding roles in logistics.

Reduced workforce requirements in the unloading area are achieved as unloading cycles can be completed in shorter periods of time, allowing companies to optimize labor allocation while maintaining or increasing throughput.

Challenges & Solutions

The major pain point in operational processes involving the unloading of loose-loaded trailers was addressed through the ErgoUnload system, which provides both ergonomic improvements and efficiency gains through a specialized unloading solution.

The high physical force requirements of 50-100% for parcel lifting in traditional unloading processes were dramatically reduced to approximately 10% through the ergonomic design of the ErgoUnload system, making the task more sustainable for operators.

System Integrator

Körber developed and implemented the ErgoUnload system as part of their portfolio of logistics automation solutions. Their expertise in addressing operational challenges in parcel logistics enabled the creation of this specialized solution that combines ergonomic design with operational efficiency improvements for trailer unloading operations.