Solving a Costly Glove Usage Problem in a Laverton Warehouse

Badger’s Client Support team was approached by a large food storage company in Laverton, Victoria, facing a significant issue with glove consumption. They had a ‘chronic glove usage’ problem and needed a solution—fast!

The Challenge: Excessive Glove Consumption

At one of their sites, 400 employees worked in chilled environments as pickers, reach truck drivers, and forklift operators. Their daily tasks included:

• Picking cartons of food and beverages
• Packing and wrapping pallets
• Operating RF scanners and writing
• Driving reach trucks

The warehouse had multiple temperature zones, ranging from 3-5°C to as low as -25°C. To keep things simple, the company provided only one type of glove—the ‘old faithful’ cotton polka dot glove. Employees working in chilled sortation wore one pair, while those in the freezer wore up to three pairs at a time.

The Cost of High Glove Usage

While the cotton gloves were inexpensive per pair, they were being consumed at an unsustainable rate. Employees would go through up to three pairs per day due to wear and tear or simply discard them at the start of each shift because they were ‘cheap.’

Weekly Usage – Cotton Gloves:

• 300 employees in chiller – 1,200 pairs per week
• 100 employees in freezer – 600 pairs per week
• Total: 1,800 pairs per week @$0.40 per pair = $720.00

Monthly Hard Costs:

With extremely high glove consumption, the company was spending up to $3,000 per month on gloves alone.

Soft Costs:

Beyond the financial burden, excessive glove usage led to additional ‘soft costs,’ including:

• Untidy corridors and carparks due to discarded gloves, negatively impacting staff morale
• Increased landfill costs due to excessive disposal
• Unnecessary environmental impact

The solution – an amazingly economical & innovative thermal glove

Badger developed an innovative, cost-effective thermal glove that lasted weeks instead of days. The Cosy CrissCross was designed with:

• Acrylic/polyester shell for superior comfort and durability
• PVC grip on both sides for extended wear life
• Reinforced thumb and forefinger crotch to withstand heavy use

These features provided a highly effective, warm, and comfortable safety glove for warehouse employees.

The Results: Dramatic Reduction in Costs and Waste

Weekly Usage – Cosy CrissCross Gloves:

• 300 employees in chiller – 75 pairs per week
• 100 employees in freezer – 25 pairs per week
• Total: 100 pairs per week @ $5.00 per pair = $500.00

Reduced Hard Costs:

By significantly lowering glove consumption, the company reduced its monthly spend to well under $2,000—a substantial improvement in cost efficiency.

Reduced Soft Costs:

With 90% fewer gloves used, the site has benefited from:

• Cleaner workspaces, improving overall morale
• Reduced landfill waste, lessening environmental impact
• A boost in staff satisfaction with warmer, brightly colored gloves

A Smarter Approach to Safety and Cost Efficiency

By switching to the Cosy CrissCross, the company transformed its glove usage, reducing both hard costs and environmental impact. This small change led to big results—proving that the right safety gear makes all the difference.