Study: Exoskeletons Centers Cut Strain and Sprain Injuries 62% at Distribution Centers

Workers wearing an exosuit experienced a 62% reduction in total strain and sprain injuries, a study examining hundreds of thousands or work hours shows.

HeroWear, an occupational exoskeleton provider, conducted a longitudinal safety data study from five distribution centers over eight to 23 months and a combined 311,000 work hours.

It found a 62% reduction in total strain and sprain injuries among workers who wore the Apex 2 exosuit. The flexible, back-assist exosuit is designed to function like an extra set of back muscles to limit strain, fatigue and discomfort. According to the suit’s maker, the lightweight exosuit helped workers at the centers lift and carry thousands of pounds of goods during case-picking shifts.

HeroWear said this was the first time data suggest that worker injury risk was not transferred to other body parts with the elastic back exosuit, but instead the findings showed meaningful reductions in back injuries, with no corresponding rise in injuries elsewhere when comparing rates before and after deployment.

Injury outcomes were tracked among logistics workers in food and beverage, retail, manufacturing, and general warehousing sectors who wore the exosuits.

The data also showed injuries decreased from previously having one every 20,000 work hours to fewer than one every 50,000 work hours.