Handling racks of product

Use solutions with the least risk

Racks are used frequently in the food industry and can be heavy or difficult to move. The filling and emptying of racks with trays often involves repetitive bending or work above shoulder height. High trolley racks can also restrict employees' visibility. The following solutions can help employers control risks to employees handling racks of product. 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 racks of product, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Manually placing trays below knee height and above shoulder height

High-risk actions that can cause an MSD

• Bending the back forwards or sideways more than 20 degrees, working with one or both hands above shoulder height, grabbing, actions with the fingers, hands and arms, lifting and 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

• Trays need to be manually placed in and out of racks below knee height and above shoulder height.

Handling solutions

Preferred solution with the least risk

• Install a conveyor system to replace racks and trolleys.

Solutions with a reduced risk

• Reduce rack size and height to improve stability, visibility and to reduce pushing forces.
• Use an appropriate, well-maintained rack with suitable handle design and configuration.
  • Vertical handles can cater for employees of differing height.
• Put in place a system where trays are not stacked below knee height or above shoulder height.
  • Ensure a higher centre of gravity does not cause the rack to become unstable.

Handling extra product stored on top of rack

High-risk actions that can cause an MSD

• Bending the back forwards or sideways more than 20 degrees, working with one or both hands above shoulder height, grabbing, actions with the fingers, hands and arms, lifting and 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

• Extra product stored on top of racks.

Handling solutions

Preferred solution with the least risk

• Install a conveyor system to replace racks and trolleys.

Solutions with a reduced risk

• Place an angled surface on top of the rack to ensure no goods are stored on top of it above shoulder height.
• If visibility is a problem when transporting full racks, allow for sight lines by not placing product in those rows.

Handling heavy fully laden racks

High-risk actions that can cause an MSD

• Using high force applying fast or jerky forces during pushing or pulling.
• Pushing or pulling objects that are hard to move or stop.

Potential source of risk

• Weight of fully laden rack.

Handling solutions

Preferred solution with the least risk

• Use mechanical tugs.

Solutions with a reduced risk

• Ensure racks have suitable wheels for the floor surface and they are regularly cleaned and maintained.
  • The configuration of the wheels and the placement of swivel wheels can also help to reduce force.
• Ensure floor surfaces are even and free of obstacles.

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.