Calculating the amortization of a lifting aid: formula, calculation example and worksheet
A lifting aid pays for itself as soon as the cost savings exceed the investment. The formula is simple: Payback period = Investment ÷ (annual savings minus annual operating costs) . The only difficulty lies in accurately quantifying the savings. This article shows step by step which items should be included in the calculation, works through a complete example with clearly stated assumptions, and provides a worksheet for your own calculations.
The most important points in brief
Two key figures are sufficient for the investment decision:
Static payback period (years) = Investment ÷ (annual savings minus annual running costs)
ROI over the useful life (%) = (Net savings per year × useful life minus investment) ÷ investment × 100
The static calculation ignores interest rates and price increases. For most lifting aids, it is still meaningful because the amortization period is short compared to the service life. Those who finance through leasing compare the annual lease payment with the annual savings instead of the investment.
The five areas for savings and how to quantify them
1. Freed-up staff time
When heavy or bulky components are lifted by two people today, the second person is tied up during every lifting operation. With a lifting aid, one person can work alone. Calculate: Lifting operations per day × time tied up by the second person × working days × hourly rate. This item is usually the largest in practice.
2. Sick days avoided
Musculoskeletal disorders are one of the most frequent causes of work incapacity. According to the AOK Absenteeism Report, 19.8 percent of all sick days in 2024 were attributable to this group of illnesses. The Federal Institute for Occupational Safety and Health (BAuA) estimates the resulting economic losses in production in 2024 at €134 billion, based on 881.5 million sick days. This translates to approximately €152 in wage costs and around €258 in lost gross value added per day. Within your own company, the costs are often higher due to additional factors such as replacement staff, overtime, and delivery delays. Assess your own value.
Our article "Musculoskeletal Disorders in Production" provides further details on the overall cost of lost production days.
3. Shorter cycle times
A lifting aid guides the load without swinging and positions it precisely. This saves time during lifting, alignment, and assembly. Measure the current time per operation and estimate the time with a lifting aid conservatively.
4. Less scrap and component damage
Edges, scratches, and dropped parts cause rework and scrap. Calculate: damaged parts per year × cost per damage.
5. Lower employee turnover
Physically demanding jobs are difficult to fill due to the skilled labor shortage. Each replacement requires recruitment and training. This cost is difficult to quantify and is therefore deliberately omitted from the calculation example.
The cost side: what belongs in the investment
Investment: Basic system, project-specific equipment, and, if applicable, control system. The price range is from approximately €10,000 to approximately €150,000; details can be found in the guide " What does a manipulator cost?"
Assembly, commissioning and training: included in the offer or shown separately, depending on the project.
Ongoing costs: maintenance, spare parts, energy and the annual safety inspection .
Service life: 15 to 25 years with good maintenance, see service life of manipulators .
Calculation example: Assembly workstation in two-shift operation
A 35 kg component is currently lifted by two employees working together, 120 times per shift, across two shifts. All figures are assumptions and serve for illustrative purposes.
Investment including installation: 40,000 euros
Ongoing costs (maintenance, safety inspection): 1,500 euros per year
Freed-up personnel time: 240 lifting operations per day × 30 seconds of time tied up by the second person × 220 working days × 45 euros per hour = 19,800 euros per year
Averted sick days: 8 days × 400 euros in operational downtime costs = 3,200 euros per year
Fewer component failures: 6 failures × 250 euros = 1,500 euros per year
Result: The savings amount to €24,500 per year; after deducting operating costs, €23,000 remains. The amortization period is 40,000 ÷ 23,000 = approximately 1.7 years, or about 21 months . Over a 15-year service life, this results in a return on investment (ROI) of approximately 760 percent. This calculation does not yet include cycle time savings or employee turnover.
Control test: without freed-up staff time
If only one person is currently using the system, the largest expense is eliminated. This leaves €3,200 plus €1,500 in savings minus €1,500 in operating costs, totaling €3,200 per year. The payback period is approximately 12.5 years. Even with a usage period of 15 to 25 years, the system still pays for itself, but at a significantly slower rate. This comparison demonstrates why a fair calculation considers each item individually.
(Illustrative calculation example. Their actual values depend on the workplace, component and process and are specifically determined in the process analysis.)
Worksheet: Your own amortization calculation
You can use this information to calculate the amortization for your workplace yourself:
Component weight and dimensions
Lifting operations per shift and number of shifts
Will two people be lifting today? If so: time allocated to the second person per lift?
Hourly rate including additional wage costs
Sick days per year at this workplace related to lifting, and your cost per day of absence
Damaged components per year and cost per incident
Current time per lifting operation and estimated time with lifting assistance
Investment as per offer and ongoing costs per year
Add up the savings per year, subtract the ongoing costs, and divide the investment by the result. That's your payback period in years.
Four typical mistakes in ROI calculation
Only count sick days: Health is the most important argument, but rarely the biggest cost factor. Personnel time and cycle time are always included.
Don't forget assembly and commissioning: Always compare the complete scope of delivery, not just the system price.
Setting too short a service life: Anyone who calculates with five years underestimates the ROI of a system that runs for 20 years.
Ignore ongoing costs: Maintenance and safety inspections are predictable and should be included in the calculation from the start.
Economic efficiency is not the only criterion.
Employers are obligated under occupational health and safety laws and manual handling regulations to assess and reduce hazards associated with manual lifting. There are no fixed kilogram limits; the decisive factor is the risk assessment, for example, using the key indicator method. If the assessment reveals a need for action, a technical solution is required, regardless of the payback period. Our article "How many kilograms can you lift?" explains how the assessment works.
Financing and funding
Those wishing to avoid a one-time investment can choose from leasing options with terms of 24, 36, or 48 months, or hire purchase with terms of 12 to 48 months, both through their financing partner Würth Leasing. If the monthly payment is less than the monthly savings, the lifting aid pays for itself from the very first month. Some employers' liability insurance associations (Berufsgenossenschaften) offer subsidies for occupational safety measures, but the conditions vary depending on the association. Check your eligibility for funding with your association before purchasing. Read more about buying, leasing, and renting in the article "Renting or Buying a Manipulator ."
This is how Zeilhofer supports you
In the process analysis, we assess the values of your workplace and calculate the amortization together with you. Afterwards, you will receive an indicative price and subsequently a fixed-price offer. Zeilhofer Handling Technology has been developing and manufacturing lifting aids, manipulators, and lifting axes for loads up to 1,200 kg in Holzkirchen since 1999, with over 2,500 systems delivered to 18 industries. We are certified according to ISO 9001 and TISAX Level 2 with prototype protection. Our product finder will show you which system is right for your needs.
Would you like to know when a lifting aid will pay for itself at your workplace? Send us your key details, and we will get back to you within 24 hours on weekdays.
Frequently asked questions about the amortization of lifting aids
How do you calculate the amortization of a lifting aid?
Payback period in years = Investment ÷ (annual savings minus annual operating costs). Savings include avoided sick days, freed-up employee time, shorter cycle times, less waste, and lower employee turnover.
How quickly does a lifting aid pay for itself?
This depends primarily on whether a second person becomes available for lifting. In the example calculation presented in this article, an investment of €40,000 pays for itself in approximately 21 months. Without freed-up employee time, it takes around 12.5 years; however, with a usage period of 15 to 25 years, the system still becomes profitable.
How much does a sick day cost?
According to the Federal Institute for Occupational Safety and Health (BAuA), the economic losses in production in 2024 amounted to €134 billion for 881.5 million days of sick leave. This corresponds to approximately €152 in wage costs and around €258 in lost gross value added per day. Within individual companies, the costs due to replacements, overtime, and lost production are often higher.
Which savings should be included in the ROI calculation?
Avoided sick days, freed-up personnel time when lifting in pairs, shorter cycle times, fewer damaged components and lower costs for fluctuation and replacement.
Which costs should be included in the invoice?
The investment for the basic system and equipment, assembly and commissioning, as well as the ongoing costs for maintenance, spare parts, energy and the annual safety inspection.
What is the expected lifespan?
Well-maintained manipulators and lifting aids achieve 15 to 25 years of economical operation. Anyone expecting shorter timeframes significantly underestimates the ROI.
Is a lifting aid worthwhile even without a quick return on investment?
Yes, if the risk assessment indicates a need for action. Employers must reduce hazards associated with manual lifting in accordance with occupational health and safety legislation and the manual handling regulations, regardless of the amortization period.
How much does a lifting aid cost?
Simple cable manipulators with hook attachments start at around €10,000, while complex lifting axis solutions can cost up to €150,000. Details are explained in the Zeilhofer guide "What does a manipulator cost?".
