Handling spindles and rolls of packaging in food manufacturing

Use solutions with the least risk

Spindles are used during the manufacture of products and for the dispensing of packaging and labels. Spindles on their own can be heavy and awkward to handle. However, the risk of a musculoskeletal disorder (MSD) is greater with a loaded spindle.

Rolls of packaging can also be heavy, wide and often require handling to change their orientation before loading. Developments in spindle cradle systems have resulted in improved loading and unloading of these devices and metal alloys have reduced the weight of spindles.

The following solutions can help employers control risks to employees who handle spindles and rolls of packaging in different situations. These solutions may 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 spindles and rolls of packaging, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Controlling risks from the location of spindle cradles

High-risk actions that can cause an MSD

• High-force lifting and lowering of heavy loads.
• Exerting force while in an awkward posture.

Potential source of risk

• Location of spindle cradle.

Handling solutions

Preferred solutions with the least risk

• Introduce an automatic system that can lift or remove a spindle from the cradle.
• Use an overhead hoist with purpose-built lifting head.
• Use an overhead gantry with a reel turner to change roll orientation from vertical to horizontal for loading.

Solutions with a reduced risk

• Use mechanical aids. For example:
  • height-adjustable trolleys to place rolls into position
  • packaging-roll trolleys
  • height-adjustable lifters
  • packaging-roll prong lifter with rollers for ease of roll movement
• Modify the spindle cradle to reduce awkward postures.
• Use team handling as an interim solution to reduce force.
• Use steps or platforms to raise employees, if appropriate.

Controlling risks from the weight of spindle and roll

High-risk actions that can cause an MSD

• High-force lifting and lowering of heavy loads.
• Exerting force while in an awkward posture.

Potential source of risk

• Weight of spindle and roll.

Handling solutions

Preferred solutions with the least risk

• Increase the size of the spindle and use mechanical aids such as:
  • an automatic system that can lift or remove a spindle from the cradle
  • an overhead hoist with purpose-built lifting head
  • an overhead gantry with a reel turner to change roll orientation from vertical to horizontal for loading

Solutions with a reduced risk

• Reduce the weight of the spindle by replacing spindles with lightweight material or just 2 ends.
• Reduce the roll weight.

Controlling risks from lifting reels off pallets

High-risk actions that can cause an MSD

• High-force lifting and lowering of heavy loads.
• Exerting force while in an awkward posture.

Potential source of risk

• Replacing reels from pallets located on the ground.

Handling solutions

Preferred lowest-risk solution

• Use mechanical aids to lift and transfer packaging rolls.

Solutions with a reduced risk

• Use height-adjustable pallet lifters.
• Use a tool to change the orientation of the reel, such as a scissor trolley.
• Store spare spindles in racks at waist level.

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.