Introduction – The Hidden Cost of Hand & Head Injuries in Logistics
Fast-paced loading docks, 24/7 forklifts and multi-shift handling mean one thing: hands and heads are always at risk. According to the U.S. Bureau of Labor Statistics, transportation & warehousing still records > 4.0 injury cases per 100 workers each year—most of them hand lacerations and head impacts from falling cartons or pallet edges.
Customer Profile
- Site: 650-acre regional distribution hub (3 PLs, 1,200 employees)
- Throughput: 180k parcels daily
- Challenge: 5 lost-time accidents per month; legacy PPE uncomfortable, often removed mid-shift
Pain Points – Why Workers Refused to Wear the Old Gear
- Gloves lost grip on plastic wrap → bare-hand handling
- Bulky hard hats rocked on neck when looking up at scanners → left in lockers
- Faded gray vests invisible to forklift drivers at dusk
Caparazon Solution – Custom 3-Item Safety Kit
- Cut-Resistant Gloves A5 – 15-gauge HPPE + sandy nitrile, touchscreen-friendly
- Bump Cap Safety Helmet – 280 g vented shell, 4-point suspension, accessory slots
- Hi-Vis Class 2 Vest – 120 g bird-eye fabric, 2″ 3M™ tape, tear-away shoulders
Add-ons: Company logo heat-transferred; employee ID badge pocket; color-coded cuff binding for shift identification.
Implementation – 3-Month Pilot
- Week 1: Fit-testing & toolbox training (Caparazon safety rep on-site)
- Week 2-4: Phased roll-out across inbound, outbound & value-add zones
- Month 2: Digital inspection via QR code on each vest (wash count / damage log)
- Month 3: Satisfaction survey & accident review
Results – Measurable Safety & Morale Gains
| Metric | Before | After 3 mo | Δ |
|---|---|---|---|
| Lost-time accidents / mo | 5 | 3 | ↓ 40% |
| PPE non-compliance observations | 47 | 5 | ↓ 89% |
| Worker satisfaction (anonymous) | 42% | 90% | ↑ 48 pts |
| Cost per accident (medical + downtime) | US $14.2k | US $8.5k | ↓ 40% |
“Switching to Caparazon was the fastest ROI we’ve seen in safety. Gloves keep grip even in freezer zones, helmets feel like baseball caps, and the vests glow under our scanners. My team actually asks for extras now.”
— Mark Thompson, CSP, Regional Safety Manager
Key Takeaway – The Right PPE Pays for Itself
In logistics, every prevented injury saves roughly $38k (OSHA 2024 avg.). For this hub, 2 fewer accidents per month = $76k annual saving, against a 12% gear cost increase.
Next Step – Book Your Free Corporate Safety Audit
Ready to replicate these numbers?
- Virtual or on-site assessment of your current PPE
- Tailored kit proposal with volume pricing
- 15-day sample delivery