Pharmaceutical material handling | Safe & Reliable Solutions

What is Pharmaceutical Material Handling?

Material handling in pharmaceutical operations covers the processes of lifting, moving, and transporting raw materials, ingredients, packaging, and finished goods within controlled environments.

Pharmaceutical material handling isn’t just about moving goods. Ensuring product integrity, protecting workers, and meeting strict regulatory standards are key. From transporting raw ingredients to handling finished products in sensitive environments, every step must balance safety, compliance, and efficiency.

Manual handling of sacks, drums, or packaging not only slows production but also puts workers at risk of injuries. This also increases the risk of contamination. With the right lifting solutions, pharma manufacturers protect workers and safeguard product quality. It will also help them to follow GMP, FDA, and ISO standards.

Material Handling in Pharmaceutical Manufacturing

Unlike general material handling, pharma operations take place in highly regulated and often sterile environments.

Common tasks include:

• Transporting powders, chemicals, and APIs (Active Pharmaceutical Ingredients) in sacks or drums.
• Lifting drums, sacks, and containers of raw materials.
• Lifting containers, reels, and packaging materials into cleanrooms.
• Moving sterile packaging and finished products such as cartons and boxed medicines into storage or distribution.

Because contamination control, hygiene, and operator safety are so critical, pharmaceutical material handling requires specialised equipment designed for ergonomics, hygiene, and regulatory compliance. Pharmaceutical equipment should be easy for workers to use. It must also reduce physical strain and meet hygiene standards.

Pharma Material Handling Challenges

Manual lifting and handling in pharma introduces risks for both operators and products.

Key challenges include:

• Ergonomic strain: Workers often lift heavy sacks or drums, leading to back, shoulder, and wrist injuries.
• Cleanroom restrictions: All equipment must be hygienic, easy to sanitise, and made from materials like stainless steel.
• Cross-contamination risks: Manual handling increases the chance of spills, leaks, or cross-contamination. Improper handling may compromise product safety.
• Labor intensity: Manual tasks reduce efficiency and can require multiple workers. Repetitive tasks such as palletising, depalletising, or moving goods across facilities causes fatigue and slows production.
• Regulatory compliance: GMP and FDA guidelines require strict traceability and handling procedures.

Each of these challenges highlights the need for ergonomic lifting solutions in pharmaceutical material handling. These solutions need to be durable, easy to clean, and safe for sensitive environments.

Why challenges matter

Manual handling in pharmaceutical manufacturing doesn’t just create discomfort for workers, it has measurable consequences for health, productivity, and compliance. Studies show that manual material handling contributes to over half a million musculoskeletal disorder (MSD) cases annually.

These commonly affect the back, shoulders, and upper limbs. Injuries cause pain and lower efficiency on the production floor. They also raise costs for treatment and compensation.

The financial impact of manual handling injuries is staggering

Globally, work-related MSDs cost between $13 billion and $54 billion every year. In the UK, manual handling injuries cost about £7.1 billion each year. This cost comes from lost workdays and compensation claims.

In many cases, these injuries account for up to 24% of all health-related absences in the workplace. For pharma manufacturers, tight margins and strict compliance mean that losses impact both profits and supply reliability.

Operational downtime is another hidden cost

A single incident of fatigue or injury can slow down batch handling or delaying shipments. 

Long-term health consequences are also a concern. Repetitive strain injuries that begin with minor discomfort can progress into chronic conditions like osteoarthritis or persistent back pain. For employees, this means lower quality of life. For companies, it means higher turnover, increased recruitment costs, and the risk of losing experienced staff.

Taken together, these factors show why addressing manual handling challenges in pharmaceutical operations is a strategic necessity. By using ergonomic lifting solutions, manufacturers lower the risk of injury. This also helps create a healthier and more stable workforce.

Solutions for Safe Pharmaceutical Material Handling

Manufacturers can overcome pharmaceutical manual handling challenges with ergonomic, hygienic, and compliant equipment tailored to their processes.

Key ergonomic handling solutions include:

• Vacuum Lifters: Stainless-steel vacuum lifters handle sacks, boxes, or drums without direct contact. They improve ergonomics, reduce spills, and minimise contamination risks.
• Stainless Steel Lifting Trolleys: Mobile, electric trolleys designed for cleanrooms and controlled environments. Perfect for moving drums, reels, and containers safely across production areas.
• Wire & Chain Hoists: Reliable lifting systems for precise handling of heavy loads, often integrated into assembly or storage workflows.
• Overhead Cranes & Jib Cranes: Flexible crane systems that extend lifting reach, cover large work areas, and support compliant lifters.

By introducing ergonomic and cleanroom-ready equipment, companies improve both operator safety and process efficiency while maintaining regulatory compliance.

Talk to a pharma lifting expert today. 

Real-World Impact: Qualiphar Case Study

Material Handling Challenges at Qualiphar

Qualiphar is a global pharmaceutical manufacturer. Employees struggled with manually lifting heavy boxes (up to 20 kg), causing fatigue, inconsistent handling, and increasing injury risk. Only the strongest workers could perform the task, leading to operational bottlenecks and workforce safety concerns.

TAWI Lifting Solution for pharmaceutical material handling

Together with our local partner in Belgium, TAWI installed two vacuum lifter systems at Qualiphar's facility. The result? More efficient pharmaceutical material handling. Every operator, regardless of strength, now lifts heavy packaging effortlessly and consistently.

Results Delivered

1. Improved productivity: Eliminated frequent rest breaks; employees worked at consistent, steady pace.
2. Enhanced employee well being: Workers no longer endure strain or risk, and morale soared.
3. Positive culture shift: Employees recognised that management prioritised their health, reinforcing trust and engagement.

Explore the full case study. 

Benefits of Ergonomic Lifting in Pharma Manufacturing

Switching from manual handling to ergonomic lifting equipment delivers measurable benefits for both workers and businesses:

• Reduce injuries: Lower the risk of musculoskeletal disorders caused by repetitive lifting.
• Improve productivity: Workers maintain a steady pace without fatigue, increasing throughput.
• Protect product quality: Touch-free handling reduces the risk of damage, spills, or contamination.
• Ensure compliance: Equipment designed to meet strict hygienic requirements simplifies audits and inspections.
• Boost employee morale: Safer, easier workflows improve job satisfaction and reduce turnover.

The Future of Pharmaceutical Material Handling

As the pharma sector evolves, material handling relies increasingly on automation, IoT, and robotics to boost efficiency, compliance, and adaptability. Some of the key emerging trends include:

Automation & Robotics

Robotic systems increasingly handle packaging, labelling, and logistics in pharma environments. These technologies improve flexibility, accuracy, and support compliance.

Smart Lifting Equipment & Predictive Analytics

IoT-powered systems offer real-time monitoring and predictive maintenance for material handling equipment. These capabilities minimise downtime and help maintain regulatory compliance by tracking usage and condition.

Autonomous Mobile Robots (AMRs) & AGVs

AMRs and AGVs are transforming intra-facility transport by autonomously moving materials while ensuring traceability and adherence to industry requirements.

Sustainability & Modular Flexibility

Connected, modular lifting systems use less energy. They adapt quickly to changing workflows. This supports lean production and sustainable operations.

By embracing these technologies, pharmaceutical companies can future-proof their operations, combining ergonomic safety with greater efficiency and digital compliance.

Lifting Solutions for Your Pharma Workflow

Every pharma operation has unique material handling challenges, from moving sensitive powders to palletising packaged goods. TAWI works closely with manufacturers to tailor lifting solutions that fit your exact workflow, space, and regulatory needs.

Our portfolio includes stainless-steel vacuum lifters, cleanroom-ready trolleys, and precision hoists. These are all designed to keep workers safe, protect product integrity, and support regulatory compliance.

Talk to our experts today about safe and reliable material handling solutions for your pharma operations.

FAQ: Pharmaceutical Material Handling

1) What is pharmaceutical material handling?

Pharmaceutical material handling involves lifting, moving, and transporting raw ingredients, packaging, and finished goods in controlled environments. Prioritising hygiene, ergonomics, and compliance with GMP/FDA/ISO standards.

2) Why is ergonomic lifting important in pharmaceutical manufacturing?

Ergonomic lifting reduces musculoskeletal injuries, improves efficiency, and helps workers perform repetitive tasks safely while maintaining cleanroom discipline.

3) Which materials can lifting solutions handle in pharma?

Common loads include sacks of powders/APIs, drums and kegs, reels, cartons, and palletised goods. You can handle these materials with vacuum lifters, stainless-steel trolleys, or hoists.

4) Are TAWI lifting solutions suitable for cleanrooms?

Yes. Cleanroom-ready equipment, often built in stainless steel, is hygienic, easy to sanitize, and compliant with industry standards.

5) What benefits can I expect from lifting solutions?

Safer workers, fewer injuries, faster production, reduced product damage, and improved compliance, resulting in measurable ROI.