Filling, weighing and stitching sacks or bags

Use solutions with the least risk

The process of filling, weighing and stitching bags or sacks often takes place in separate stages at different workstations. Bags often require lifting and lowering numerous times to complete the process. This lifting and lowering exposes employees to risks from repeatedly bending and twisting with heavy loads.

The following solutions can help employers control risks to employees filling, weighing and stitching sacks or bags in different situations. These solutions may help eliminate or reduce the risk of employees developing a musculoskeletal disorder (MSD).

Solutions are listed in order, from those considered most effective to those considered less effective.

Employers should make sure employees use the handling solutions with the least risk, so far as reasonably practicable.

Solutions with reduced risks are an alternative only if least-risk methods are not reasonably practicable.

Employers should start implementing risk controls for the heaviest or highest-volume products first.

The following guidance also describes high-risk actions that can cause an MSD. Employers have a duty to eliminate or reduce the risk of MSDs so far as is reasonably practicable, and should make sure employees do not perform high-risk actions, if practicable.

Consultation

So far as reasonably practicable, employers must consult with employees and any health and safety representatives (HSRs) when identifying hazards and providing risk control measures. Consultation should include discussions about how employees will fill, weigh and stitch bags, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Filling, weighing and stitching bags at different stations

High-risk actions that can cause an MSD

• Back bending and application of sustained awkward posture:
  • more than twice per minute or
  • more than 30 seconds at a time

  for more than 30 minutes continuously or more than 2 hours over the whole shift. These actions may occur while filling, weighing and stitching bags or sacks or in combination with other work activities.

• High-force lifting and lowering heavy loads.

Potential source of risk

• Filling, weighing and stitching stations are at different heights and locations.
• Weight of bags.

Handling solutions

Preferred solutions with the least risk

• Fully automated bagging machines.
• Integrate weighing scales and an automatic stitching machine within the conveyor process by:
  • using a hopper or fill station that delivers a measured amount of produce to eliminate the requirement to weigh separately
  • installing an automated or electronic shut-off mechanism
  • providing a belt conveyor to transfer bags
  • using an automatic stitching machine

Solutions with a reduced risk

• Elevate scales from the floor to reduce lifting and lowering from the weigh station or place scales on a trolley to transport them between the filling and stitching station or fill bags on scales.
• Install a pneumatic lifter that lifts, lowers and supports bags to reduce manual lifting and lowering.
• Reduce the weight in each sack or bag in combination with other risk controls that improve posture and movement.

  Note: Reducing the weight of bags may increase the frequency of handling and, depending on circumstances, may not reduce the risk.

Holding a stitcher

High-risk action that can cause an MSD

• Holding a tool:
  • for more than 30 seconds at a time for more than 30 minutes continuously or
  • for more than 2 hours over the over the whole shift

  These actions may occur in the situations listed or in combination with other work activities.

Potential source of risk

• Holding a stitcher.

Handling solutions

Preferred solutions with the least risk

• Use an automatic stitching machine.
• Use alternative sack-sealing methods to eliminate the need for machine stitching.

Solutions with a reduced risk

• Suspend or use counterbalance to support weight of stitcher.

Manually operating chute open-and-close valves

High-risk action that can cause an MSD

• High-force manual operation of the chute open-and-close valve.

Potential source of risk

• Manual operation of the chute open-and-close valve.

Handling solutions

Preferred solution with the least risk

• Automate the chute open-and-close valve.

Solutions with a reduced risk

• Extend the length of the lever and provide a padded handgrip.
• Reduce the weight in each sack in combination with other risk controls that improve posture and movement.

Note: Reducing the weight of bags may increase the frequency of handling and, depending on circumstances, may not reduce the risk.

Your legal duties

Employers

The Occupational Health and Safety Act 2004 (OHS Act) requires employers to provide and maintain a working environment that is safe and without risks to health, so far as reasonably practicable. An employer contravenes this duty if they fail to:

• provide or maintain plant or systems of work that are, so far as reasonably practicable, safe and without risks to health
• make arrangements for ensuring, so far as reasonably practicable, safety and the absence of risks to health in connection with the use, handling, storage or transport of plant or substances
• maintain, so far as is reasonably practicable, each workplace under the employer's management and control in a condition that is safe and without risks to health
• provide, so far as is reasonably practicable, adequate facilities for the welfare of employees at any workplace under the management and control of the employer
• provide information, instruction, training or supervision to employees of the employer as is necessary to enable those employees to perform their work in a way that is safe and without risks to health

Employers also have an obligation to consult, so far as is reasonably practicable, with employees and any HSRs on matters related to health and safety that directly affect them, or that are likely to directly affect them. This duty to consult also extends to independent contractors, including employees of the independent contractor, engaged by the employer in relation to matters over which the employer has control.

Employees

While at work, employees also have duties under the OHS Act to take reasonable care for their own health and safety and the health and safety of others who may be affected by their acts or omissions in the workplace. Employees must also co-operate with their employer's actions to make the workplace safe and comply with the OHS Act and Regulations.

The WorkSafe website has guidance about the occupational health and safety (OHS) responsibilities of employers and employees.