How Upgrading Casters Improved Ergonomics and Efficiency in a Pharmaceutical Manufacturing Facility
Pharmaceutical and biotechnology manufacturers rely on efficient, ergonomic material handling to maintain productivity, safety, and compliance in clean manufacturing environments. However, outdated casters and wheels can create hidden bottlenecks—causing carts to bind, increasing operator strain, and disrupting picking and dispensing workflows. In this case study, we explore how a large pharmaceutical manufacturer upgraded its picking cart casters with CC Apex® casters, dramatically improving mobility, ergonomics, and consistency across multiple departments while meeting strict clean manufacturing requirements.
Overview
A large pharmaceutical and biotechnology manufacturer operating a multi-department facility in the Northeastern United States was facing long-standing mobility and ergonomics issues with its picking carts and dispensing bins. After years of struggling with outdated phenolic wheels and unreliable swivel casters, the manufacturer partnered with Caster Connection to evaluate a more ergonomic, clean-compatible caster solution.
The result was a facility-wide upgrade that significantly improved cart mobility, reduced operator strain, and standardized caster performance across departments.
The Challenge: Poor Mobility in a Clean Pharmaceutical Environment
The manufacturer relied on hundreds of stainless steel picking carts and dispensing bins to move materials throughout its facility. These carts were used daily in controlled, pharmaceutical-grade environments where cleanliness, consistency, and reliability were critical.
However, the existing caster setup created several persistent problems:
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Hard phenolic wheels that required excessive force to start rolling
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Swivel casters that frequently bound or locked, reducing maneuverability
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Increased physical strain on employees during repetitive cart movement
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Ongoing complaints that had persisted for five to six years
Because the carts operated in clean areas, any replacement solution also had to meet strict requirements:
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Stainless steel compatibility
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No exposed lubricants or contaminants
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Smooth, predictable rolling to support ergonomic workflows
The Solution: CC Apex Casters Designed for Performance and Clean Use
Caster Connection provided the customer with a test set of CC Apex casters, a versatile caster solution known for smooth rolling performance, superior swivel action, and durability in demanding industrial applications.
The selected configuration — 3” × 1.25” CC Apex casters (DC-7510-300125-40-T6) — was well-suited for the customer’s lightweight stainless steel carts and frequent directional changes common in picking and dispensing operations.
Addressing Clean Manufacturing Requirements
During the evaluation process, the customer identified concerns related to anti-seize compound visibility and chemical composition on the caster axles. This was a critical issue, as any exposed materials could pose a contamination risk in pharmaceutical environments.
Caster Connection responded by:
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Providing a full chemical breakdown of the anti-seize compound used during assembly
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Working cross-functionally with internal product and engineering teams
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Adjusting the assembly process so the anti-seize was fully concealed within the bearing
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Ensuring no residue could transfer to carts, operators, or cleanroom surfaces
Once these adjustments were implemented, the casters met the facility’s cleanliness and compliance expectations and were approved for rollout.
The Results: Facility-Wide Adoption and Measurable Improvement
The impact of the CC Apex casters was immediate and highly visible.
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Picking carts rolled more easily and smoothly
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Swivel action improved, eliminating frequent lock-ups
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Operators reported better control and reduced effort when moving carts
The improvement was so significant that other departments began borrowing the upgraded carts for their own operations. This unexpected internal demand led to additional orders and rapid expansion of the project.
Key Outcomes
- One department replaced casters on approximately 200 carts
- Additional departments quickly followed
- Full facility-wide implementation was completed within weeks
- The new caster solution outperformed what the customer had been using for over five years
According to customer feedback, the upgraded casters delivered dramatically better performance compared to the previous phenolic wheels and swivel casters.
Why It Worked: Matching the Right Caster to the Application
This project succeeded because the solution addressed more than just wheel replacement. Caster Connection focused on:
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Compatibility with pharmaceutical clean manufacturing standards
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Consistency across departments to prevent operational bottlenecks
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Real-world testing before full-scale implementation
By combining product expertise with responsive engineering support, Caster Connection helped the customer move from a long-standing problem to a scalable, facility-wide solution.
Takeaway: Ergonomic Casters Make a Measurable Difference in Pharmaceutical Operations
In pharmaceutical and biotech manufacturing environments, inefficient material handling can quietly erode productivity and increase employee fatigue over time. This case demonstrates how upgrading to the right caster solution can:
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Improve ergonomics and operator safety
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Increase efficiency in picking and dispensing workflows
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Reduce long-term frustration caused by poor mobility
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Support clean manufacturing and compliance requirements
The CC Apex caster proved to be a reliable, clean-compatible solution that delivered lasting performance improvements across an entire pharmaceutical facility.
Looking for a Caster Solution for Pharmaceutical or Clean Manufacturing Applications?
Caster Connection works with pharmaceutical, biotech, and clean manufacturing facilities to design caster solutions that improve ergonomics, efficiency, and compliance.
Start with a Caster Needs Evaluation to connect with a caster expert and get a mobility solution tailored to your application.
