Sauleda Eliminates the Strain of Fabric Roll Handling with TAWI
Lifting fabric rolls required two people and was a physically exhausting process. Sauleda consulted TAWI to design a safer, faster, and more efficient process.
Sauleda is a premium manufacturer of technical fabrics. When Sauleda opened a new logistics centre in Avinyó (Barcelona), they made an important decision that many companies put off until it's too late: to build ergonomics into the facility design from day one. Rather than waiting for manual handling issues, injuries or sickness absence to emerge, Sauleda planned a safer and more efficient way to move heavy fabric rolls before operations began.
Why ergonomics should be planned, not improvised
Manual handling of heavy, repetitive loads is one of the main risk factors in any production process. When designing a new facility or logistics centre, businesses have an opportunity to consider how every load will be lifted, moved and positioned.
Addressing ergonomics at the planning stage can help identify potential risks before the site is operational and before warehouse operatives begin experiencing physical strain. That was the approach Sauleda took at its new Avinyó logistics centre, when they contacted TAWI before material handling became a serious problem.
The challenge: heavy rolls & two operators per movement
At the new Avinyó facility, operatives repeatedly handle technical fabric rolls weighing between 22 kg and 42 kg throughout the working day. Without lifting equipment, each movement required two people.
This created a physically demanding process, with potential manual handling risks and additional time needed to coordinate each lift. It was a process worth improving before the facility opened, rather than after problems developed.
The solution: safer handling with vacuum lifters
From the outset, Sauleda integrated a TAWI vacuum lifter for moving fabric rolls. The system enables one operative to lift, move and position each roll in a controlled, guided movement, significantly reducing the physical effort involved in manual handling.
The suction cup adapts to the size and weight of the rolls and holds the load securely while the operative guides it into position.
The result is a faster process that no longer depends on physical strength or coordination between two people, precisely because it was designed this way from the beginning, rather than added later.
The results: faster & more efficient
Since integrating the TAWI vacuum lifter into daily operations, Sauleda’s production and warehouse teams have seen a clear improvement. A task previously completed by two people can now be handled by one operative, with a noticeably quicker and less physically demanding workflow.
The solution also helps reduce the strain associated with repeatedly moving loads of up to 42 kg, supporting a more ergonomic working environment.
"We've made body posture much easier and reduced the strain on the person. We always work this way now, and operators are happy because it spares them an extra effort that, after 8 hours of work, really takes its toll," said Modest Vega, Logistics Hub Manager.
Sauleda’s experience demonstrates that ergonomics is not an optional extra or simply a cost: it is a design decision. When manual handling is considered from the start of a production or warehouse project, businesses can scale their operations while helping to protect the people who make that growth possible.
TAWI supports businesses across a wide range of industries with roll handling solutions designed to improve safety, efficiency and ergonomics.
Planning a new production process or warehouse layout? Get in touch with our team to find the right lifting solution for your needs.
Discover how Sauleda, a textile manufacturer, integrated a TAWI vacuum lifter from day one of constructing its new logistics centre in Avinyó (Barcelona).