Handling and removing product from trays, racks or tins

Use solutions with the least risk

Removing product from trays, racks or tins can be difficult in the food industry. It often results in banging or hitting of trays or tins to remove the product, which can lead to a musculoskeletal disorder (MSD) over time. Many racks and trays are hot and they are often quite large and heavy making them difficult to handle.

The following solutions can help employers control risks to employees removing product from trays rack or tins in different situations. These solutions may help eliminate or reduce the risk of employees developing an 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 handle and remove product from trays, racks or tins, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Product sticks to trays

High-risk actions that can cause an MSD

• Excessive bending of the wrist and very fast movements when hitting or banging trays and holding an object:
  • 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 in the situations listed or in combination with other work activities.

• High-force actions hitting or banging trays.

Potential source of risk

• Product has stuck to trays.

Handling solutions

Preferred solutions with the least risk

• Automate the process.

Solutions with a reduced risk

• Grease trays so products can slide.
• Use tray and tin coatings such as baking paper, spray-on lubricants or non-stick surfaces to ease the removal of product.
  • Non-stick surfaces may require regular maintenance and re-coating.
• Introduce appropriately designed job rotation in combination with other risk controls that improve posture and movement.
  • Ensure that rotation does not include other jobs with hitting actions.

  Note: Job rotation does not eliminate manual handling hazards. WorkSafe has guidance to help eliminate or reduce the health and safety risks associated with job rotation.

Weight of trays

High-risk actions that can cause an MSD

• Excessive bending of the wrist and very fast movements when hitting or banging trays and holding an object:
  • 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 in the situations listed or in combination with other work activities.

• High-force actions hitting or banging trays.

Potential source of risk

• The weight of the trays.

Handling solutions

Preferred solution with the least risk

• Automate the process.

Solutions with a reduced risk

• Grease trays so products can slide.
• Reduce the size and weight of trays.

Requirement to transport trays

High-risk actions that can cause an MSD

• Carrying a load:
  • more than twice per minute or
  • for more than 30 seconds at a time

  for more than 30 minutes continuously or for more than 2 hours over the whole shift. These actions may occur in the situations listed or in combination with other work activities.

Potential source of risk

• Transporting of trays.

Handling solutions

Preferred solution with the least risk

• Introduce conveyors or roller beds to move trays from one production process to another.

Solutions with a reduced risk

• Stack trays on trolleys for transporting from one process to the next.
• Use detachable handles to improve gripping and reduce exposure to hot trays.

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.