Moving materials is a critical part of manufacturing processes. It’s also one of the most common sources of worker injury. Heavy lifting, repetitive motions, and awkward postures lead to sprains, strains, and other musculoskeletal disorders that keep employees off the job and slow operations. According to the U.S. Bureau of Labor Statistics (BLS), manufacturing accounts for 15% of all private-sector injuries, making it the second most injury-prone industry.
When workers get hurt, U.S. employers pay out for rising workers’ compensation premiums, medical expenses, time off, fines, and more. In 2023 alone, those costs added up to $176 billion across all sectors. For manufacturers, injury-related downtime can be especially detrimental to profitability.
Reducing workplace injury risk requires a holistic approach, but one especially powerful solution is also one of the simplest: gravity conveyors. By establishing a smooth, controlled material flow, these ergonomic conveyor systems help manufacturers protect workers, reduce injury rates, and keep production steady. Here’s how gravity conveyors make it possible.
Manual material handling has long been one of the leading causes of workplace injuries in manufacturing. From heavy lifting to navigating tight, congested lineside spaces, workers deal with significant risks every day. These dangers are amplified by just-in-time (JIT) production pressures, which push teams to move quickly and handle parts frequently, often in awkward positions.
The resulting injuries aren’t minor. According to the National Safety Council (NSC), overexertion and bodily reaction injuries resulted in the most Days Away, Restricted, or Transferred (DART) cases in 2022. However, the costs involve much more than just lost productivity. As the most recent Liberty Mutual Workplace Safety Index highlights, overexertion involving outside sources alone costs U.S. businesses $12.49 billion annually, while other exertions or bodily reactions (including injuries from awkward postures) add another $3.68 billion.
Responsibility for these injuries and their costs rests squarely on employers. The Occupational Health and Safety Administration (OSHA) emphasizes that employers must not only train and support workers but also implement direct workplace solutions that address hazards at the source.
Gravity conveyors are a practical way to tackle these risks and stay compliant, minimizing manual handling and creating safer, more ergonomic workflows on the manufacturing floor. By relying on gravity to move materials efficiently through production, they help eliminate many of the most common hazards of manual handling.
Here are three ways using gravity conveyors in manufacturing can lessen worker exertion and improve their safety.
Unnecessary walking, lifting, and repetitive handling of heavy or awkward parts are among the biggest injury sources in manufacturing. Gravity conveyors let materials flow freely from one work area to the next, minimizing manual touches and keeping workers in more ergonomic, controlled positions. They’re also designed to trim travel time and handling steps, creating leaner workflows that move parts more efficiently while reducing the odds of strain and overexertion.
Gravity conveyors can be strategically positioned to deliver components at optimal heights and reach angles in order to reduce bending, stretching, and awkward reaching. Having materials directly at the point of use supports more natural body movements and promotes healthier working postures. Over time, using an ergonomic conveyor system leads to lower injury rates, less fatigue, and greater productivity.
Unlike powered conveyor systems, gravity conveyors rely on a simple, energy-free design with no motors or electrical components. This helps prevent injuries from powered equipment components and dampens noise levels on the floor. The controlled movement of parts also helps maintain a more organized and predictable workflow. Ultimately, it reduces chaos so operators can focus on value-added tasks rather than constantly shuffling materials.
There are many ways to configure gravity conveyor systems for manufacturing environments. UNEX offers several types, along with a range of accessories to customize your setup for maximum worker safety.
All conveyor types are adjustable to optimal working heights, allowing operators to keep materials within reach and minimize bending or overextension.
You can also outfit each system with various accessories to further enhance manufacturing ergonomics. Beneficial add-ons include:
With numerous ways to configure these systems, gravity conveyors represent one of the most adaptable safety solutions for production and assembly environments. From staging parts and moving materials through assembly lines to streamlining packing areas, manufacturers can easily adapt conveyors to different applications and layouts. Here are just a few cases where they support safer workflows.
Gravity conveyors play a key role in facilitating material flow within storage and picking environments. In manufacturing supermarkets and lineside workstations, gravity conveyors act as takeaway lanes, helping operators quickly move kits or components from part picking areas to assembly or staging. This supports lean principles like first-in, first-out (FIFO) flow while also reducing manual handling and minimizing walking distance.
When paired with gravity flow rack solutions like FlowCell or Roller Rack for storage, conveyors aid in the replenishment process, ensuring parts are picked and moved throughout the facility more ergonomically.
Gravity conveyors can integrate with inspection, kitting, or assembly workstations, reducing material handling and supporting more efficient line-side processes. Workers avoid constant lifting, carrying, or reaching across cluttered tables, and items arrive right where they’re needed. Packers are free to focus on careful packing and quality checks rather than material handling. It’s a straightforward approach that keeps packing lines moving smoothly, even when demand surges.
Gravity conveyors are ideal for feeding components directly to the point of use on assembly lines. Since these systems can be configured to the proper height, workers can easily access parts without excessive bending, twisting, or reaching.
Modular work cells are especially effective on assembly lines where products, components, or order mixes change frequently. By arranging conveyors and workstations into flexible, self-contained cells, manufacturers can quickly adjust layouts to support new models or fluctuating production volumes.
Each conveyor is engineered to order, ensuring a perfect fit for your exact layout and ergonomic needs. Modular designs allow you to select from a range of widths, roller materials, and support configurations to suit your specific workflows and product mix, whether you need them for lineside feeding, packing stations, or facilitating better flow in storage areas.
Constructed from durable steel or aluminum frames, Gravity Conveyor can withstand the demands of high-volume manufacturing environments with minimal maintenance. It’s a reliable, long-lasting solution that keeps operations running smoothly and workers safer for years to come.
Efficient material movement is only one benefit of using gravity conveyors for manufacturing. These systems also help you create a safer workplace for your employees, and a safe production floor ultimately yields greater productivity in the long run.
Ready to create a leaner, safer, and more efficient manufacturing environment? Contact UNEX to design a gravity conveyor system tailored to fit your facility.