Handling packaging materials

Use solutions with the least risk

Boxes are often delivered as heavy packets of collapsed or flat boxes. These are often stored on pallets on the ground and the flat packs are fed manually into a packaging unit that is machine-paced.

The following solutions can help employers control risks to employees transferring packaging materials from the ground into packaging units. 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 handle packaging materials, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Boxes on a pallet on the ground

High-risk actions that can cause an MSD

• Bending the back more than 20 degrees, twisting or turning, actions with the hands or arms, lifting or lowering and exerting force while in an awkward posture more than twice per minute:
  • 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.

Potential source of risk

• Boxes on pallets that are on the ground.

Handling solutions

Preferred solution with the least risk

• Introduce automated box-assembly equipment.

Solutions with a reduced risk

• Raise the height of a pallet by using a pallet lifter or a combination lifter and mover.
• Use spare pallets to raise the height of the pallet.
• Use a stand to raise the height of the pallet.
• Depending on size of packages, use team lifting.
• Job rotation.

  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.

Heavy packs of cartons

High-risk actions that can cause an MSD

• Using high force lifting, lowering or carrying heavy loads.
• Exerting high force while in an awkward posture.

Potential source of risk

• Heavy weight of packs.

Handling solutions

Preferred solutions with the least risk

• Introduce automated box-assembly equipment.
• Use a vacuum lifter.

Solutions with a reduced risk

• Request supplier provide fewer flat packs in each packet.
• Depending on the size of packages, use team lifting in combination with the preferred risk solutions.
• Job rotation.

  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.

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.