LOGISTICS CASE STUDY

National 3PL Provider: 1,200 Workers, 30 Distribution Centers

How a national 3PL provider can save an estimated $423,700 annually with centralized respirator compliance across 30 locations in 18 states

Illustrative scenario — modeled on typical customer economics at published pricing; not a named customer account.

1,200

Warehouse Workers

86%

Cost Reduction

$424K

Annual Savings

30 sites

Distribution Centers

Company Overview

A nationwide third-party logistics provider operates 30 distribution centers across 18 states. The company employs 1,200 warehouse workers including forklift operators, hazmat handlers, order pickers, and shipping/receiving personnel.

Workers require respirators for hazmat operations, chemical spill response, cleaning operations, and exposure to warehouse dust and diesel exhaust. Managing compliance across 30 locations created fragmented recordkeeping and high costs.

The Challenge: Zero Visibility Across 30 Locations

Multi-Location Compliance Nightmare

• Each facility used different local occupational health clinics (30 different providers)
• Clinic costs ranged from $120-$200 per evaluation depending on location
• Corporate EHS had zero visibility into compliance status across locations
• 5 FTE safety coordinators spent 15+ hours/week managing clinic relationships = $312,500/year
• Annual medical evaluation cost: ~$180,000 (estimated $150 average across the $120-$200 clinic range × 1,200 workers)
• Total annual cost: $492,500

The Solution: Enterprise Platform with SSO & API Integration

The company deployed RespiratorTest.com's enterprise platform with SSO integration (Okta), API connection to UKG HRIS for automated employee sync, and centralized dashboard for corporate EHS oversight.

98%

Compliance Rate

All 30 locations

$423K

Annual Savings

86% cost reduction

4.5

FTE Eliminated

Admin time savings

4 weeks

Full Rollout

All 30 locations live

Year 1 ROI: 567%

Initial investment (setup + training): $75,000. Annual savings: $423,700. Payback period: 2.1 months. Three-year projected savings: $1,271,100.

"RespiratorTest.com transformed our respirator compliance program. We went from managing 30 clinic relationships and chasing down paper records to having real-time visibility across all locations from a single dashboard. The SSO integration and API connection to our HRIS eliminated 95% of our administrative work. Best EHS investment we've made."

Vice President of Environmental Health & Safety

Multi-Location Logistics Provider

Ready to Centralize Your Multi-Location Respirator Compliance?

Join 50+ enterprise organizations managing respirator compliance across 10+ locations with RespiratorTest.com. SSO, API integrations, unlimited locations, and dedicated support.

Book Enterprise Demo View Enterprise Solution

The compliance baseline in this story: 29 CFR 1910.134(e)(1) requires a medical evaluation before any employee is fit tested or uses a respirator, at every location. Across 30 sites, a single missed step repeats 30 times — and OSHA's 2026 maximum is $16,550 per serious violation.

Related Resources

Enterprise Compliance Platform

Multi-location dashboards, bulk invitations, role-based access.

Enterprise respirator compliance →

Online Medical Evaluation

The OSHA Appendix C evaluation each employee completes online.

Online respirator medical evaluation →

Multi-Location Guide

How distributed teams keep every site inspection-ready.

Multi-location compliance guide →