Cut Trailer Unload Time in Half with ErgoRider: Live From PROMAT 2025 with Caljan
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Warehouse innovations take center stage at PROMAT 2025, as Kevin chats with Alex Sturm, Senior Account Manager at Caljan, to explore how the ErgoRider is reshaping loose-loaded cargo handling.
Caljan, a Denmark-based logistics equipment manufacturer founded in 1963, has long been a trusted provider of durable, ergonomic conveyor systems. Now making a strong push into the U.S. market, Caljan is tackling one of the industry’s most pressing challenges: the physically demanding task of loading and unloading loose-loaded trailers.
In this episode, Alex walks us through the features of the ErgoRider, an integrated platform and conveyor belt system mounted on Caljan’s Performer Telescopic Conveyor. The ErgoRider addresses labor shortages, improves safety, and boosts operational throughput—all with a user-friendly design that can cut unload times in half.
The ErgoRider is Tackling the Toughest Part of the Job
Loading and unloading loose cargo from trailers is often the most grueling—and injury-prone—part of warehouse operations. Caljan’s solution aims to change that.
“With a telescopic, anything that is loose that’s in a trailer can be loaded and unloaded… at a very, very efficient, fast speed where you can cut your time, possibly even down to a half.”
According to Alex, the ErgoRider helps reduce trailer dwell time from 2–3 hours to just around one hour. That faster turnaround means better yard flow, fewer bottlenecks, and improved labor productivity. Ergonomics is also a key focus, especially as employee retention becomes more difficult in high-churn areas like container unloading.
Floating Innovation: The Power of the ErgoRider
What sets the ErgoRider apart isn’t just what it does, but how it does it. It hovers.
“We are free-floating. We hover over. We never touch the trailer.”
Traditional systems that rest on the trailer floor can damage dock plates or trailers. The ErgoRider’s free-hanging design avoids this by staying completely off the trailer deck. The result is safer operation and less wear and tear on equipment. It’s also flexible: with powered vertical and horizontal adjustment, workers can easily position the belt exactly where needed, whether lifting from the floor or reaching for top-loaded cartons.
“This gives you the ability to bring the belt to the box… very easy to get something that’s one, two feet down on the bottom or up at seven, eight feet high.”
The platform is intuitive to operate, featuring simple controls akin to a pallet jack. Built-in LED lighting also addresses one of trailers’ most overlooked safety issues: darkness.
ErogRider: Safe, Easy to Install, and Easier to Use
For all its innovation, getting the ErgoRider up and running is remarkably simple. Caljan’s engineering team works directly with the customer to match facility layout, dock configuration, and operational needs.
“We have very different sizes… it could be a smaller one or a larger one. Depending on what product you have, we’ll make that work.”
Whether you’re moving cartons, bags, or irregular cargo, Caljan will tailor the solution to match belt width, loading patterns, and conveyor integration. Power and mounting are straightforward; once installed, operators can be trained on Day 1.
“Very simply gets bolted down. We just need power from your facility. You’re ready to go.”
Key Takeaways on ErgoRider
- Cuts trailer loading/unloading time by up to 50%, reducing dwell time from 2–3 hours to ~1 hour
- Free-hanging design never touches the trailer floor, reducing damage and increasing safety.
- Fully adjustable platform with powered vertical/horizontal controls brings the belt to the box.
- LED lighting improves visibility inside dark trailers
- Ergonomic operation reduces employee strain and increases retention in high-churn jobs.
- Simple installation with flexible sizing options and CAD-supported planning
- Supports unloading of up to 6 trailers per dock per shift
Listen to the episode below and leave your thoughts in the comments.
Guest Information
For more information on Caljan, click here.
To connect with Alex on LinkedIn, click here.
Check out the podcasts below for more information about trailer unloading solutions like Caljan’s ErgoRider.
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