HP Valves deploys German Bionic exosuits to strengthen worker safety and productivity

At HP Valves in Hengelo, The Netherlands, the future of manufacturing is already part of daily operations. The Dutch specialist for high- and medium-pressure valve solutions has integrated German Bionic exoskeletons into its machining department to better protect employees during physically demanding lifting and handling tasks — and to strengthen productivity at the same time.

Automated machining runs around the clock, and frequent pallet handling places sustained strain on the workforce. Even with established ergonomic measures in place, HP Valves looked for a smarter approach to reduce physical load and long-term health risks. The result: a connected, data-driven solution that supports lifting, bending, carrying and walking — smart, AI-based robotic exoskeleton tech from German Bionic.

In just the first 200 hours of use on the shop floor:

• More than 6,000 lifts were supported

• Over 130,000 kg of weight was compensated

• 230,000+ steps with active walking assistance were taken

“The exoskeleton is a great investment. I can see that it improves employee well-being, while at the same time helping us maintain productivity and reduce potential health risks,” says Lukasz Babiniec, Manager Machining at HP Valves.

And from the shop floor: “The exoskeleton makes my back feel less strained and allows me to work more comfortably throughout the entire day,” adds Krzysztof Kazmierski, FMS Operator.

What stands out is not just the immediate relief for the operators, but the measurable impact on fatigue reduction, ergonomics, and daily well-being – creating a safer, healthier and more attractive working environment in long-term industrial operations. This is human-centric wearable #robotics where it matters most.