Insoles or anti-fatigue mats? Both provide helpful ergonomic support, but which provides the best long-term return on investment? Three factors can help you make informed buying decisions – cost, quality, and value. We explore each below.
Insoles or anti-fatigue mats, which solution provides better ROI? Below are several important factors to consider.
1. Cost – Insoles vs. 100-1 Series Anti-Fatigue Mat
The average pair of generic and non-customized orthotic insoles costs $40. Custom insoles are often around $100 per pair. For this example, we will use the generic $40 insoles. consider a distribution center with 100 employees.
100 x $40 per pair of insoles: $4,000
Insoles are designed to last 3-6 months. Higher-quality insoles can last up to 2 years depending on use. For workers who stand on hard surfaces for ~6 hours a day, podiatrists recommend replacing insoles every 4 months or roughly 650-700 working hours.
If the $40 insoles were replaced every 4 months:
Yearly cost for insoles: $12,000
Conversely, industrial grade anti-fatigue mats like the AcroMat 100-1 Series, designed for industrial, retail and food processing environments, costs $14 per square foot.
For this example, the distribution needs 10 4 ft. by 20 ft. anti-fatigue mats (800 total square feet) to accommodate all 100 employees. One 4 ft. by 20 ft. mat costs $1,120.
The mat comes with a Lifetime Performance Warranty which promises the mat will never curl along the borders, sink, flatten, or lose its ergonomic cushion. No pair of insoles comes with a cushion guarantee. If any of these issues were to happen, the mats would be replaced free of charge. These guarantees are backed by OSHA-accredited, third-party laboratory testing.
The 100-1 Series anti-fatigue mat comes a useful life expectancy of 3-8 years in heavy industrial settings, years longer in lighter settings. The mat is impervious to liquids and chemicals, antimicrobial, and can be cleaned regularly to extend its useful life without fear of the material breaking down.
The AcroMat 100-1 Series is guaranteed not to curl, sink or flatten, and can be customized to any shape and size to cover complex layouts.
10 100-1 Series mats for 100 people: $11,200
If the mat lasts 3 years: Total cost $3,733/year
If the mat lasts 5 years: Total cost $2,240/year
If the mat lasts 8 years: Total cost $1,400/year
Cost Winner: 100-1 Series Anti-Fatigue Mat
Related: How Do Anti-Fatigue Mats Work?
2. Quality and Value – Insoles vs. 100-1 Series Anti-Fatigue Mat
Both insoles and anti-fatigue mats are designed to reduce pressure on the feet, legs, back, and neck. This includes promoting healthy blood flow which reduces risks of cardiovascular issues, and preventing overexertion by helping your body "share the load. However, research shows the results between insoles and mats are very different.
According to a webinar titled Anti-Fatigue Mats and Their Relationship to MSD Prevention, hosted by the Centre of Research Expertise for the Prevention of MSDs, there is "moderate" evidence that anti-fatigue mats help reduce pain and discomfort.
Comparatively, there is "very limited" evidence insoles do the same. Further, "insoles impact the geometry of the shoe" which can increase the risk of slips, trips, and falls because there's less balance and control in fast-moving areas.
A key reason for the difference in results is the fact that insoles go flat over time, while AcroMat's molded nitrile rubber never sinks, flattens, or lose its ergonomic cushion. Insoles have to be replaced every 4 months to 2 years, while AcroMat anti-fatigue mats can perform upwards of 8 years without interruption.
Quality and Value Winner: 100-1 Series Anti-Fatigue Mat
This custom 100-1 Series anti-fatigue mat for Nokian Tyres has been in use for 2 years inside a 24/7 manufacturing facility (16,000+ hours). The 100% nitrile material is guaranteed to never flatten or lose its cushion.
Watch: Amanda Eskew, EHS Specialist with Nokian Tyres, and three of her operators, including the operator pictured in the photo above, share their experience with AcroMat.
Related: The Best Anti-Fatigue Mat Material: 100% Nitrile vs. PVC Foam
3. Pro/Con Summary
Here is a brief summary of key differences between insoles and AcroMat anti-fatigue mats.
Insoles:
I. Specific to the individual, not the facility or workspace.
II. Podiatrists recommend replacing insoles every 4 months to maintain proper foot health and support.
III. Proper orthopedic insoles provide excellent ergonomic cushion; however insoles don't support traction.
IV. Insoles leave with the employee, i.e., they are turnover prone.
V. Easy to order in bulk, roughly $40 per pair for generic insoles:
100 pairs for 100 employees x $40 per pair: $4,000
If replaced every 4 months: Total cost $12,000/year
AcroMat anti-fatigue mats:
I. Can be designed to any shape/size to fit complex layouts; designed to elevate an entire workspace and its team.
II. Support employees across all shifts, e.g., a 24/7 facility with three shifts would need one custom mat vs. 3X the insoles.
III. Turnover proof, mats don't leave with employee departures.
IV. NFSI Certified for "High Traction," proven to reduce wet-slip risks by 50-90%.
V. Backed by a lifetime cushion and no-curling warranty, overall life expectancy 5-8+ years.
10 4 ft. x 20 ft. AcroMats for 100 employees: $11,200
If the mats last 5 years: Total cost $2,240/year
If the mats last 8 years: Total cost $1,400/year
4. Regardless of Approach, Focus on Your People
MSD or ergonomic injuries are the No. 1 cause of workplace injuries, and high on the list in terms of most preventable workplace injuries. Each year, MSD injuries lead to 364 million missed days of work globally.
In an industry that relies on workers being available and productive, the risk of not having an anti-fatigue solution in place is far greater than the cost. Both insoles and anti-fatigue mats provide valuable benefits. The key is uncovering which solution answers the most pressing needs of your workforce.
Pro Tip:
You're not limited to insoles if you have a large, complex layouts. At AcroMat, we have the ability to customize our anti-fatigue mats to any shape and size to the inch, including curves, cutouts, custom angles, and more. Consider this custom anti-fatigue mat for a leading window and door manufacturer:
