Carton Handling and Order Picking: Protect Your Operators, Keep Your Throughput

Quick summary

Musculoskeletal Disorders (MSDs) account for 35% of all work-related ill health in Great Britain (HSE, 2024). In warehouses and distribution centres, order picking is one of the leading causes.

Two pieces of equipment address this:

Mobile Order Picking Arm – SWL 50 kg, designed for picking under racking beams, no fixed infrastructure required
Mobile Jib Crane – up to 100 kg, for transfers between zones and heavy reels
Browse all our equipment in our handling solutions by industry.

Why does order picking cause so many MSDs?

An order picker performs between 800 and 1,200 picks per day. The physical demands are relentless:

Back flexion under racking beams
Arms raised above shoulder height when reaching for high shelves
Trunk rotation when placing loads on pallets
Strain accumulates from the second hour onwards

HSE guidance “Getting to grips with manual handling” (INDG143) identifies the ideal grip height between 0.75 m and 1.25 m. Below or above this range, biomechanical risk increases sharply. Most picking workstations operate outside this safe zone.

The Unpredictability Problem

The real challenge with picking is load variability. An operator might pick:

A 5 kg carton
Then a 25 kg bag
Then a 40 kg drum

Operators cannot adjust their posture for every pick. This constant adaptation exhausts stabilising muscles and causes injury. A warehouse cannot reserve picking for the most physically robust staff – high turnover, tight recruitment, and mixed teams mean every operator profile must maintain pace.

A workstation equipped with a Mobile Order Picking Arm allows every operator to maintain throughput without physical strain.

Which equipment for warehouse order picking?

Two pieces of equipment cover all use cases. Choose based on load weight and working zone.

Equipment	SWL	Use case	Key advantage
Mobile order picker	50 / 100 kg, mounted on all types of electric pallet truck	Picking below rack bars: cartons, bags, buckets, canisters. Palletising.	Under-bar picking, front and vertical gripping, removable battery pack
Mobile jib crane	70 / 100 kg (50 and 70 kg with extended arm at 2.70 m), 350° rotation	Transfers between areas, pallet unloading, heavy reels and drums	Mobile base, no floor fixing required, smooth movement

The right gripper for every load

Cartons and Parcels: Vacuum Suction Cups and Vacuum Box

Bags: Bag Suction Gripper

Buckets, Drums and Canisters: Round Suction Cup or Hook Tool

Reels and Cable Drums: Expanding Mandrel

Non-Standard and Bespoke Loads: Spreader Bar and Custom Grippers

Cartons and Parcels: Vacuum Suction Cups and Vacuum Box

Two grippers available.

Multi-format vacuum suction cups provide instant grip on smooth and semi-smooth surfaces, with no marking on the carton. Ideal for standard cardboard boxes and mixed formats.

The vacuum box is a universal, ultra-lightweight carbon gripper: designed to handle a variety of loads (cartons, wooden boards), it can grip several cartons simultaneously, accelerating throughput at high-volume workstations. The Mobile Order Picking Arm operates under racking beams from 467 mm floor height.

Bags: Bag Suction Gripper

The bag suction gripper is designed specifically for picking neck-sealed bags, cement bags, granule bags and condiment sacks. Its shape and structure are adapted to the soft, irregular surfaces of bags, providing a firm grip with no risk of spillage – even on bags stacked loosely in varying orientations.

Buckets, Drums and Canisters: Round Suction Cup or Hook Tool

Two options depending on the container.

The round suction cup is positioned on the lid of the bucket or drum: its circular shape ensures perfect contact on flat and slightly domed surfaces.

For buckets and canisters fitted with a handle or bail, the hook tool grips the handle directly, with no contact with the body of the container.

Bobines et tourets : pince à expansion

The expanding mandrel is inserted into the core of the reel or cable drum and provides a firm, secure grip through mechanical expansion.

It enables sustained throughput across variable formats without manual adjustment, and guarantees free rotation of the reel during placement with no contact on the windings.

Non-Standard and Bespoke Loads: Spreader Bar and Custom Grippers

Available in two versions (SWL 50 kg and SWL 100 kg), the Mobile Order Picking Arm is the reference equipment for warehouse order picking. One objective: to allow an operator to pick loads under real picking conditions, without physical strain.

Technical specifications:

SWL 50 or 100 kg depending on version: covers all common picking loads
Working height from 467 mm floor level: operational under standard racking beams
Full mobility: free movement in aisles, operational within a few hours
Autonomous charge 8 to 12 hours: one charge covers a full working day
Interchangeable grippers without tools: vacuum cups for cartons, bag gripper, expanding mandrel for reels, hook tool for handles

Front grab / Mobility / Fluidity / 100 kg CMU

Front grab / Mobility / Fluidity / 100 kg CMU

Mobile order picking arm: built for picking under racking beams

Picking manipulator
50 & 100 kg

The Mobile Order Picking Arm is the reference solution for order picking operations in warehouses. It is operational under standard racking beams from 467 mm floor level.

Mountable on all types of electric pallet trucks, it gives the operator full mobility across aisles without requiring fixed infrastructure or installation downtime.

Available in two versions:
50 kg SWL - standard picking operations
100 kg SWL - heavy cartons, drums, and mixed loads

Discover the Mobile Order Picking Arm

Mobile order picking arm 100Kg

Ideal for picking cartons, drums, bags, buckets and canisters up to 100 kg.

Mobile jib crane: for load pick-and-place operations

Mobile Jib Crane 70 & 100 kg

The Mobile Jib Crane is the handling solution for all your pick-and-place operations and load transfers.

Available in 70 kg and 100 kg versions, with 350° rotation, 2 m reach (2.70 m option available), and lifting height adjustable from 2.5 m to 3.8 m.

Like the Mobile Order Picking Arm, your Mobile Jib Crane requires no floor fixing and no external power supply. Repositioning takes a few minutes.

Discover the Mobile Jib Crane

Mobile Jib Crane 100Kg

Your solution for pick and place of cartons, drums, bags, buckets and canisters up to 100 kg.

I noticed the difference right away. Normally I feel a lot of pain after handling the parts, but thanks to the SCARA arm, I feel much better!

Operator - A.U.T

Thanks to NEODITECH's picking cobot, we have been able to integrate female staff into our handling operations for heavy household appliances. The result: improved well-being at work and reduced risk of MSD.

Gaëtan Pineau - U LOG

Read the testimonials of our customers who have transformed their businesses thanks to our solutions. Improved productivity, optimized mobility: their success is now yours.

Reduce MSD risk and its cost to your business

Investing in ergonomic lifting equipment is not just a health and safety obligation – it is a measurable business decision.

HSE Manual Handling Operations Regulations 1992 require you and your employer to avoid, assess and reduce manual handling risks where reasonably practicable. Failure to comply can result in HSE improvement notices, prohibition notices or prosecution.

The cost of inaction is significant. HSE estimates the average cost of a work-related MSD absence at £8,000 to £12,000 per case – including sick pay, temporary cover, lost productivity and potential liability claims. At 800 to 1,200 picks per day, a single picking workstation without ergonomic support is a recurring liability.

Your Employers’ Liability insurance premiums are directly influenced by your accident and absence record. Documented ergonomic interventions – including equipment installation and operator training records – support lower risk ratings at renewal.

Access to Work (UK Government scheme) can fund your workplace adaptations for health conditions or disabilities, including ergonomic handling equipment. Applications are made through Jobcentre Plus.

Important note on the Mobile Jib Crane: the crane in its fixed floor-mounted version may qualify for different funding routes than the mobile wheeled version. Our team will advise you on the most appropriate configuration for your situation.

Our teams support you through every step of the process. You do not have to manage this alone.

Loads over 100 kg: beyond 100 kg, an overhead crane or forklift is more appropriate for your operation.
Fully automated systems with no operator: if your objective is a goods-to-man system with no human intervention, our equipment is not the right answer.
Very small items (under 500 g): a precision gripper or automated picking system is better suited to your needs.

What this solution does not cover

FAQ

Frequently asked questions about carton handling and ergonomic order picking

Which industrial manipulator is right for carton handling and order picking in your warehouse?

For order picking and carton handling in your warehouse, the right equipment is the Neoditech Mobile Order Picking Arm. It is designed for order preparation operations in racking, including under shelf beams from 467 mm floor level. Its integrated pallet truck arm allows you to grip the load, move it from point A to point B, and place it – without physical effort and without ever lifting it manually. It handles cartons, bags and drums fully autonomously, with no fixed infrastructure, on a single 8 to 12-hour charge. The Mobile Jib Crane covers all your other handling and pick-and-place operations, particularly for supplying production lines, up to 100 kg.

How do you handle cartons under racking beams without MSD risk?

The Neoditech Mobile Order Picking Arm is designed for these confined spaces. Fitted with multi-format vacuum suction cups, it grips the carton and transfers it to the pallet without you bending your back. At 800 to 1,200 picks per day, that is the difference between a sustainable workstation and a recurring absence.

Does the Mobile Order Picking Arm work on all your warehouse floors?

Yes, on all standard industrial floors: smooth concrete, epoxy resin, industrial tiles. Stability is provided by integrated counterweights and a parking brake. For very uneven floors or loading dock ramps, a preliminary site assessment is recommended.

Can the same equipment handle cartons, bags and drums?

Yes. The Mobile Order Picking Arm accepts interchangeable grippers: vacuum suction cups for cartons, bag suction gripper for bags, round suction cup or hook tool for drums and buckets. Changeover without tools in a few seconds. One piece of equipment covers all your loads on a multi-reference workstation.

What financial support is available for ergonomic picking equipment in the UK?

The HSE Manual Handling Operations Regulations 1992 create a legal obligation to reduce your manual handling risk – non-compliance carries enforcement and liability costs that typically exceed the cost of the equipment. Employers’ Liability insurers reward documented ergonomic interventions with lower risk ratings. The UK Government’s Access to Work scheme can fund your workplace adaptations for eligible employees. Our team will help you identify the most relevant route for your situation.

Neoditech in logistics: on-site presence

French designer and manufacturer since 2007, based in Mouzillon (Loire-Atlantique, France), Neoditech supports more than 575 customers across France and Europe. Our sales engineers visit your warehouse, analyse your picking workstations and propose the right configuration – before selling you anything. All our equipment complies with the Machinery Directive 2006/42/EC and carries CE marking.

We design solutions that combine ergonomics and productivity. Our equipment enables manufacturers to improve operator safety while optimizing their production processes. NEODITECH is also :

Customers supported in France and Europe

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Manipulators sold in France and elsewhere

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Take action

Order picking does not have to remain the most physically demanding workstation in your warehouse. The equipment exists. Our sales engineers visit your site free of charge, analyse your workstations and propose the right solution – with no obligation.

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