Photo Courtesy: Gorbel
When Frogg Toggs, a full-spectrum distribution center in Alabama, began looking for ways to improve its container unloading process, the company was searching for a better way to work.
“Our business primarily is big-box retailers, but we also do a great deal of direct-to-consumer small parcel shipping. In our operations, we have no one who is devoted solely to container unloading, so everyone who is unloading containers has other primary jobs,” said Kelly Douglas, Operations Manager at Frogg Toggs.
For many warehouse and distribution operations, that challenge is familiar. Containers arrive daily, but unloading them is rarely anyone's primary responsibility. Associates are pulled away from picking, replenishment, inventory management, shipping, and other critical workflows whenever inbound trailers arrive.
"Traditional/unassisted container unloading is very labor intensive and inefficient," Douglas said. "The man hours that must be devoted to container unloading and the physical toll it takes on the associates needed to be reduced. We began looking into various equipment to help alleviate some of the strain of receiving and unloading floor-loaded containers."
The impact of manual unloading extends beyond labor hours. It can create operational bottlenecks, slow dock door turnover, increase associate fatigue, and make it more difficult to keep pace with growing customer expectations.
"As labor becomes harder to find and customer expectations continue to increase, many organizations are taking a closer look at the hidden costs associated with manual unloading," said Stefan Friedrich, Product Marketing Manager at Gorbel.
"They're evaluating not only labor hours, but also injury-related expenses, dock congestion, storage and demurrage charges, and employee turnover. As a result, more operations are looking for practical ways to improve the experience at their loading dock,” Friedrich said.
Rather than leading with equipment, Carolina Handling focused on understanding the operation, identifying bottlenecks, and recommending a solution aligned with Frogg Toggs' business goals. The result was a partnership-driven approach that improved efficiency, reduced labor demands, and created a positive experience for associates.
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Container unloading can be especially challenging because it remains one of the most physically demanding jobs in the warehouse.
"Workers are constantly reaching, bending, twisting, lifting, and carrying products in confined spaces," Friedrich said. "And trailers can get hot, especially in the summer. Those extreme temperatures increase fatigue and injury risk."
Photo Courtesy: Gorbel
From an operational perspective, unloading can also become a significant bottleneck.
"When trailers take longer to unload, dock doors turn more slowly, labor utilization suffers, and product takes longer to reach inventory," Friedrich said. "In an environment where labor shortages are common and throughput expectations continue to rise, those inefficiencies add up quickly."
For Frogg Toggs, every hour spent unloading containers represented time associates could not spend supporting other value-added activities throughout the facility.
Carolina Handling's consultative approach begins with understanding operational objectives before recommending technology.
"That's a great thing about Carolina Handling. We are focused on bringing you the best solution and to partner with you and to partner with the company that we are going to bring the solution to you,” said Ethan Alford, Applications Engineer at Carolina Handling.
That approach stood out to Frogg Toggs during its evaluation process.
"Carolina Handling was very helpful in researching and exploring all options in the industry," Douglas said.
After evaluating the operation, Carolina Handling recommended Destuff-it, a portable ergonomic conveyor system from trusted material handling partner Gorbel®.
Photo Courtesy: Gorbel
The recommendation was driven by operational outcomes, not technology alone. The solution offered an opportunity to increase throughput, improve dock utilization, reduce labor requirements, enhance associate safety, and support future growth without increasing headcount.
According to Friedrich, the system's design was built around both productivity and ergonomics.
"The Destuff-it system was designed to bring the worker to the product and let the conveyor do the heavy lifting," Friedrich said.
"Our adjustable operator platform elevates associates to an ergonomic working position so they can access product safely without relying on step stools, excessive reaching, or climbing on boxes. The pivoting conveyor allows operators to slide boxes directly onto the belt rather than repeatedly lifting and carrying them,” Friedrich said.
Friedrich said these design elements help reduce physical strain while simultaneously improving throughput.
"The result is a solution capable of achieving case rates exceeding 1,200 cases per hour while helping reduce worker strain, fatigue, and injury risk," he said.
The impact was measurable almost immediately.
"A typical container would take us 2 or 3 hours to unload with a stepladder and a manual roller system. Very time-consuming, very inefficient. Utilizing the Destuff-it, a container typically takes an hour to an hour and a half, and we generally use two fewer people,” Douglas said.
The labor savings were significant, but according to Douglas, the true value extended much further into the operation.
"The primary benefit of the Destuff-It is the reduction in man-hours needed to unload a typical container, but that has many secondary effects in the overall operations of the warehouse," Douglas said. "Associates are able to return to their primary responsibilities more quickly and the disruption to the work day and each individual department is minimized."
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While reducing unload times was the initial goal, Frogg Toggs experienced additional operational benefits after implementation.
"We have four receiving doors for our containers. We have one Destuff-it in use that can be utilized across all four doors," Douglas said.
The mobility of the system allows the operation to quickly reposition equipment wherever it is needed, supporting receiving efficiency across multiple docking locations without requiring dedicated equipment at each door.
Douglas also cited the system's versatility as a key advantage.
"The design of the Destuff-It provides versatility and ease of movement, allowing the equipment to be moved from one truck bay to another quickly and easily. It also allows both sides of the line to be unloaded simultaneously without taking up a great deal of space."
That flexibility becomes especially valuable when handling diverse inbound shipments.
"The long conveyor line helps with more complex cargo loads when there may be dozens of different products coming down the line continuously," Douglas said.
He also noted that the system occupies less floor space than other solutions the company evaluated and can be quickly disassembled and reassembled when not in use.
"Having those individuals unload a container as quickly and efficiently as possible so they can return to their primary responsibilities is paramount, and that's one of the best benefits of the Destuff-it," Douglas said.
Faster unload times can improve dock utilization, accelerate inventory availability, and help operations respond more effectively to changing demand.
"The ROI on a Destuff-it can be anywhere from 6-12 months, depending on how many containers you are unloading. But the return on investment is very high. Very fast and very high," Alford said.
As leaders evaluate opportunities to improve warehouse performance, many are also expanding the way they think about return on investment.
"We encourage leaders to start with their operational goals at the dock door," Friedrich said. "Are they struggling with labor availability, throughput, injuries, dock congestion or similar challenges? That's a good sign that it's worth evaluating a solution like Destuff-it."
He recommends benchmarking existing performance and establishing clear improvement goals before beginning an evaluation.
Friedrich also encourages organizations to consider the full business impact of container unloading operations.
"Labor savings are important, but many customers also see value through faster trailer turns, improved dock utilization, reduced injury exposure, lower employee turnover, and fewer operational charges related to delays and congestion," he said. "When all of those factors are considered together, the business case is very compelling."
While productivity metrics often drive investment decisions, operational improvements also affect the people performing the work every day. Reducing repetitive bending, lifting, climbing, and reaching can greatly improve morale.
“All of our associates love using the Destuff-it. It's much safer, much more efficient. The ease of use, the versatility, expected cost of ownership, and the expected return on investment made Destuff-it the clear choice,” Douglas said.
Photo Courtesy: Gorbel
Friedrich believes that balance between productivity and workforce support is what makes the solution unique.
"Destuff-it is a great example of worker augmentation," Friedrich said. "Rather than automating associates out of the process, it helps them work safer, faster, and more comfortably."
He added, "When a customer can unload trailers faster, reduce physical strain on their workforce, and create a more efficient operation at the same time, everyone wins."
“It makes you feel really good at the end of the day because you know you've made the whole customer's operation run smoother,” Alford said.
Carolina Handling's goal is to help customers solve operational challenges by combining industry expertise, consultative guidance, and the right technologies for the application.
For Frogg Toggs, the challenge was the efficiency of container unloading. Carolina Handling's role was not simply recommending equipment. It was helping the customer evaluate available options, understand the tradeoffs, and identify the solution best aligned with its operational goals.
The result was a partnership between Frogg Toggs, Carolina Handling, and Gorbel's Destuff-it team that delivered measurable business outcomes, improved labor utilization, and created a better experience for associates.
A consultative approach remains at the core of how Carolina Handling helps organizations improve productivity, optimize warehouse operations, and prepare for future growth.
Whether you're struggling with labor availability, dock congestion, safety concerns, or increasing throughput demands, evaluating your container unloading process can uncover opportunities to improve efficiency and better utilize your workforce. Here are answers to common questions warehouse leaders may when exploring unloading solutions.
How do I know if it's time to rethink my floor loaded container unloading process?
Short answer: It may be time to evaluate a new approach if your operation experiences:
Start by benchmarking your current process and identifying the operational improvements you want to achieve.
What types of operations benefit most from Destuff-it?
Short answer: Destuff-it is well-suited for facilities that:
What are the key benefits of Destuff-it?
Short answer: Destuff-it helps organizations:
How does Destuff-it improve associate safety?
Short answer: The system is designed to bring associates to the product while the conveyor handles movement. This reduces repetitive bending, lifting, carrying, climbing, and reaching, helping minimize fatigue and physical strain. Destuff-it™ includes built in safety features, such as e-stops, hand-present sensors, a front sensing edge on the operator platform to stop movement when activated, pressure sensing safety mats, an operator pressure sensing mat, and LED light strips to improve visibility in the trailer.
What should leaders consider when evaluating the ROI of Destuff-it?
Short answer: Look beyond labor savings. Consider:
A broader view often reveals even greater long-term value.
Does Destuff-it replace associates?
Short answer: No. Destuff-it is designed to augment the workforce, helping associates work safer, faster, and more comfortably while allowing them to spend more time on higher-value activities.
How quickly can organizations see results from Destuff-it?
Short answer: Results vary by operation, but organizations often experience immediate productivity improvements through faster unloading, improved labor utilization, and more efficient dock operations.