How exoskeletons reduce injuries in warehouses and logistics

Warehouse and logistics operations in Canada present a high rate of musculoskeletal injuries (MSIs) due to repetitive movements, heavy lifting, and awkward postures. With a workforce that is aging and increasing pressure on productivity, many companies are turning to ergonomic technologies. Among these, industrial exoskeletons stand out as one of the most effective solutions.

This guide explains how exoskeletons reduce injuries, what Canadian companies are actually observing in the field, and why training is essential to maximize results.

1. Why warehouses are risky environments

Workers in distribution centers and logistics platforms repeat hundreds of movements per shift:

• repeated bending

• lifting and lowering loads

• prolonged static positions

• walking long distances

• handling bulky items

• tasks at shoulder height or above

In Canada, over 40% of time-loss injuries involve the back, shoulders, or upper limbs. These injuries lead to significant financial, operational, and human costs.

2. How exoskeletons reduce injuries

Exoskeletons such as the LiftSuit, Wave, and Japet.W+ support the body during demanding tasks. They reduce muscle load, improve posture, and lessen fatigue.

2.1 Reducing lumbar load

Field studies show a decrease of 25 to 30% in lumbar muscle activation, thus reducing stress related to bending and lifting.

2.2 Improving posture

Exoskeletons encourage safer movements, limiting compensations and excessive bending angles.

2.3 Decreasing fatigue at the end of the shift

By redistributing effort, workers complete their tasks with less discomfort, which reduces the accumulation of micro-traumas.

2.4 Supporting shoulders and arms

Upper body models, like the Deltasuit, reduce overload during order preparation and handling tasks.

2.5 Ergonomic consistency

Unlike human postures that degrade when fatigued, the exoskeleton offers constant support throughout the shift.

3. Results observed in Canada

In warehouses in Ontario, Quebec, British Columbia, and Alberta, companies that have integrated exoskeletons observe:

• a notable reduction in lumbar fatigue

• an improvement in handling postures

• a decrease in reported discomfort

• an increase in satisfaction and well-being

• an improvement in productivity in physical roles

Although official statistics are rarely shared, feedback converges: a decrease in micro-injuries and better overall comfort.

4. Training: a key element

The benefits do not manifest on the first day. Like any specialized equipment, the exoskeleton requires a learning period.

At Exoskeletons Canada, each trial includes:

• practical training

• a demonstration of correct movements

• personalized adjustments

• on-site support

This approach ensures rapid and safe adoption.

5. Roles that benefit most from exoskeletons

Gains are particularly visible in the following tasks:

• order preparation

• repetitive handling

• palletizing

• handling irregular loads

• long periods of standing

• loading and unloading

Positions with frequent lumbar or shoulder fatigue are the first to benefit from a trial.

6. Return on investment (ROI)

Canadian companies often see significant improvements within the first few weeks:

• fewer temporary assignments

• reduction in lost hours

• decrease in WSIB claims

• better operational consistency

• improved employee retention

These gains directly contribute to overall productivity.

Conclusion

Exoskeletons are transforming injury prevention in warehousing and logistics in Canada. By reducing muscle load, improving posture, and limiting fatigue, they support workers as well as operational performance.

Success rests on three pillars:
the right exoskeleton, adequate training, and structured support.

To plan a trial in your company, contact Exoskeletons Canada.