Tico Terminal Sees 71% Push Force Reduction on Carts with Twergo® - Caster Concepts

Overexertion Complaints Turned Into Compliments After Twergo Casters Installed On Carts.


Tico Terminal is the largest terminal tractor fleet owner and operator in North America, providing equipment and services in the port, terminal, distribution, logistics, and intermodal space.

And like many busy manufacturers, material handling carts keep the assembly lines moving.

A challenge for Tico revolved around 4 cart designs that were extremely heavy and hard to push.  Overexertion injuries were increasing, with multiple strains to elbows, shoulders, and upper back as well as a very long list of complaints.

Between all 4 cart designs used in various locations, up to 118 operators would handle these carts daily. Push forces on these carts can get up to 120 lbs. when full– needless to say it was a big ergonomic challenge!  And this was not an isolated incident.


The company’s ergonomist, Dave Castleman, sat down with me to review the issues Tico was having with their carts. Dave explained the top 4 carts that they were having trouble with. I took precise measurements to determine what size caster was needed and provided three sets of Twergo® casters for a trial run.

I was fully confident that the casters would solve the push force problems the company was having. And in the words of Mr. Castleman, “Boy was Paul right. After trialing the casters on the 4 cart designs, we’ve seen an immediate 71% reduction in push force!”


A major reduction like this was very unexpected and appreciated because the ergonomist had never gotten these types of results from a caster change/upgrade before.  This push force reduction also thrilled the cart operators. By switching to Caster Concepts’ Twergo casters, more than 60 High-Risk Tasks were eliminated, affecting over 500 total cart operators.

The question now was, would these results hold up over time?

“In my 23-year professional career in ergonomics, I have used good and even great casters, but the results slowly but surely dwindle as the caster wears down over time, notes Mr. Castleman. “Although blown away from the results of these casters when they were new, I expected the same diminishing results from the Twergo casters.  However, I was again blown away!”

After 3 years in full and heavy production, the Twergo casters have only lost about 1% of their original gain.  Dave has pushed the Twergo casters into many of the company’s other North American sites, and has now started ramping up sister sites in South America, Europe, and Asia.  Dave HIGHLY RECOMMENDS the TWERGO Caster to any customer regardless of industry type.