18 Sep 2025
THE HIDDEN COSTS OF MANUAL LIFTING: WHY BUSINESS ARE SWITCHING TO ELECTRIC HOISTS
THE COST OF DOING NOTHING
Every year in the UK, workplace injuries linked to manual handling quietly drain billions from businesses. According to the Health & Safety Executive (HSE), 543,000 workers suffered from work-related musculoskeletal disorders (MSDs) in 2023/2024, resulting in nearly 8 million lost working days. That's not just a safety issue - it's a productivity crisis.
For many companies, the assumption is simple: manual lifting is "free." After all, workers are already being paid, and a chain or pulley doesn't cost much. But this logic hides the real truth: manual lifting is slow, inconsistent, and expensive in the long run.
This article uncovers the hidden costs of manual lifting, and demonstrates why UK businesses across logistics, manufacturing, construction, and beyond are turning to electric chain hoists as a smarter, safer, and more cost-effective solution.
Manual handling may look cheap, but the reality is it costs UK businesses billions each year in injuries, downtime, and lost productivity
THE PROBLEM WITH MANUAL LIFTING
HEALTH & SAFETY RISKS
- MSDs remain one of the most common workplace health issues in the UK
- HSE reports that 20% of all workplace injuries stem directly from manual handling
- Common outcomes: back injuries, repetitive strain, and joint problems
PRODUCTIVITY LOSS
Manual handling is not only dangerous but also slow:
- Workers fatigue quickly
- Tasks must be rotated to prevent overuse injuries
- Load limits mean more time spent splitting heavy lifts into smaller batches
FINANCIAL COSTS
Manual handling has a compound cost:
- Direct Costs: injury claims, higher insurance premiums, sick pay
- Indirect Costs: lost productivity, temporary staff cover, retraining, and overtime.
CALCULATING THE HIDDEN COSTS
This is where the real damage becomes visible. Businesses often fail to account for how inefficiency, injuries, and downtime snowball into major expenses.
WORKPLACE INJURY COSTS IN THE UK
- HSE estimate that workplace injuries and ill health cost UK employers £20.7 billion in 2022/23
- MSDs alone cost around £3.5 billion annually in lost production and healthcare
- Average cost of a single workplace injury claim: £14-20k
THE SILENT KILLER: LOST PRODUCTIVITY
Even when no injury occurs, productivity loss is enormous.
- A fatigued worker lifts fewer loads per shift
- Injuries often result in short-term sick leave - slowing workflows
- Teams are forced to reallocate duties, disrupting efficiency
ROI SNAPSHOT: ELECTRIC HOIST VERSUS MANUAL HANDLING
| Cost Factor | Manual Lifting (Annual) | Electric Hoist (Annual) |
|---|---|---|
| Sick Pay & Claims | £50,000 | <£5,000 |
| Lost Productivity | £70,000 | £10,000 |
| Insurance Premiums | Rising Year on Year | Stabilised / Reduced |
| Equipment Investment | Minimal upfront | £2,500–£7,500 (average) |
| Total Cost | £120,000+ | £15,000–£20,000 |
💡 This chart illustrates the potential annual savings when switching from manual lifting to electric hoists. Figures shown are estimates and will vary depending on workload, industry, and site conditions.
WHY BUSINESSES SWITCH TO ELECTRIC HOISTS
This is where the advantages of electric chain hoists become clear.
SAFETY BENEFITS
- Removes manual strain → drastically reduces MSD risks
- Features like overload protection, emergency stop, and limit switches ensure safe operation
- Wireless & pendant controls keep operators at a safe distance
PRODUCTIVITY GAINS
- Faster lifting cycles compared to manual hoists
- Consistent performance without fatigue
- In manufacturing, switching to electric hoists has been shown to increase throughput by up to 40%
Every second saved in material handling compounds into hours of extra productivity by the end of the week
COST EFFICIENCY
- Fewer claims = lower insurance premiums
- Less downtime = fewer overtime and agency staff costs
- Hoists are a long-term asset with lifespan measured in decades, not years
COMPLIANCE MADE SIMPLE
- Electric hoists simplify meeting UK regulations such as LOLER & PUWER
- Inspections and certifications become easier to maintain
CASE STUDIES
- Manufacturing Plant (South Yorkshire): After adopting electric chain hoists across three production lines, manual handling injuries dropped by 40% in one year.
- Construction Contractor (London): Portable electric hoists cut manual lifting by 80% on-site, reducing claims and accelerating project timelines.
- Automotive Supplier (Coventry): Reported a 20% reduction in downtime, saving over £150,000 annually.
BEYOND COST SAVINGS: STRATEGIC BENEFITS
Switching to electric hoists isn’t just about money - it’s about positioning your business for long-term success.
- Employer Branding: Safer workplaces attract and retain skilled staff.
- Sustainability: Electric hoists consume less energy than pneumatic alternatives and contribute to UK Net Zero 2050 targets.
- Future-Proofing: Smart hoists with IoT monitoring and predictive maintenance are already emerging, giving early adopters a competitive edge.
THE FUTURE IS ELECTRIC
Manual lifting may look cost-free, but the evidence is overwhelming: it’s expensive, unsafe, and inefficient. Electric hoists offer the safety, speed, and return on investment that modern UK businesses can’t afford to ignore.
At LES - Lifting Equipment Store, we’ve helped companies in manufacturing, logistics, and construction switch from manual to electric hoists - and reap the benefits almost immediately. With decades of expertise and strong partnerships with world-leading brands, we’re the go-to supplier for businesses looking to upgrade their lifting solutions.
Manual lifting is yesterday's solution - electric hoists are the future of safe, efficient industry
EXPLORE ELECTRIC HOISTS WITH US
👉 Browse our full range of lifting hoists & electric hoists
👉 Learn more about Delta Electric Hoists
👉 Compare models like Yale Electric hoists, CM Lodestar, and Stahl Chain Hoists
👉 Read more about electric chain hoists in our knowledge hub
👉 Or contact our experience team of experts for tailored advice
Disclaimer: All cost and savings figures provided are indicative estimates based on industry averages and HSE data. Actual savings will vary depending on workload, industry, workforce size, equipment use, and site-specific conditions.
