Advanced Handling

  • Aftersales

Ergonomic pallet loading

Client:  Thorntons PLC

Location: Derby, United Kingdom

Industry: Confectionery – Food Manufacturing

Application: Low profile scissor tables

Outcome Features: Ergonomic solution reducing manual handling and improving safety

For over 100 years Thorntons have been making delicious toffee, fudge and chocolates. Thorntons is now seen by the great British public as the ultimate chocolate treat on the high street. With around 500 stores across the UK, everyone has their favourite Thorntons chocolate.

This case study shares a common manual handling challenge where manual loading and unloading forms part of an operation and shares a solution for reducing manual handling risks and improving safety and productivity.


The originating challenge for our client was the safety risks of manual handling as operators load and unload product.  One of the highest causes of absence from work is from (MSD) muscular-skeletal disorders and specifically back related strain.  Our client wanted to introduce an ergonomic solution which would reduce lifting, reaching and bending for their operators. Through a benchmarking process Advanced Handling were selected to supply a manual handling solution based primarily on lead time but at the same time remaining cost effective.


After a site visit to see the operation the agreed solution was to install low profile scissor lifts. These scissor lifts are electrically controlled by the operator to raise or lower to ensure they can adjust the load to suit their own individual working height. A specially designed profiled ramp was also included as part of the solution to reduce potential trip hazards and to allow for direct loading of Euro pallets.

Installation & Outcome:

The benefit outcome for Thorntons has been two fold; enhancing operational efficiencies and providing employees with an improved ergonomic environment.

This case study is a great example of how sourcing the correct lifting equipment will provide significant progression for your business with a relatively modest investment.

Thorntons PLC