Handling tubs or containers of products

This guidance can help employers control the risks to employees handling tubs or containers of products in the food manufacturing industry.

Shape

Use solutions with the least risk

Employees often have to move tubs and containers of products from one location to another for further processing. Sliding tubs of material can involve exerting force in an awkward posture. It can increase the risk of developing a musculoskeletal disorder (MSD). Factors such as the type of floor surface and the size and type of wheels can affect the effort needed to push and pull tubs and other containers.

The following solutions can help employers control risks to employees handling tubs or containers of products and working with loaded heavy trolleys. 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, as 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 tubs or containers of products, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Working with heavy trolley and load

High-risk actions that can cause an MSD

  • High-force pushing and pulling objects that are hard to move or stop.

Potential source of risk

  • Heavy trolley and load.

Handling solutions

Preferred solutions with the least risk

  • Use conveyors.
  • Use a tug to move containers or trolleys.
Man using jack to lift a pallet
Using a mechanised tug to transport loads.

Solutions with a reduced risk

  • Reduce size of the container or alter the trolley to reduce the force required to move the load. For example, increase the diameter of the wheels.
  • Use team handling as an interim solution.
Two employee's pushing a tub on wheels
Team handling.
An employee pushing a scissor trolley with product on it.
A scissor trolley.

Transporting products

 

High-risk actions that can cause an MSD

  • High-force pushing and pulling objects that are hard to move or stop.

Potential source of risk

  • Requirement to transport product.

Solutions

Preferred solutions with the least risk

  • Use conveyors.
  • Use a tug to move containers or trolleys.

Solution with a reduced risk

  • Use a trolley to transport product.

Trolley hazards

Trolleys are a potential hazard source. The following information highlights potential hazards with trolleys and provides guidance on risk controls.

Design

Hazard

  • Poor trolley design results in a high centre of gravity. Pushing on uneven surfaces may tip the trolley.

Risk controls

  • A height-adjustable spring or scissor trolley will allow loading at a good height and provide a low centre of gravity for stability when pushing.
  • Place heavier items at base to reduce centre of gravity.

Handles

Hazard

  • No handles provided or handles are too low so employees apply force in awkward postures.

Risk control

  • Good handles provided. For example, vertical handles will fit a wide range of users.

Number of trolleys

Hazard

  • Insufficient number of trolleys available results in over-stacking. Trolley loads are stacked too high or exceed rated load limits.

Risk controls

  • Provide a sufficient number of trolleys, also allowing for maintenance and repairs.
  • Limit height to which trolleys can be stacked.
  • Have load rating marked on trolleys.

Castor choice

Hazards

  • Flat tyres or flat spots make the trolley difficult to get moving when manually pushed or pulled.

Risk control

  • Solid tyres or tyres with adequate tyre pressure.

Hazard

  • Small-diameter castors or wheels.

Risk controls

  • Large-diameter castors or wheels.
  • Low-resistance bearings.

Floor surfaces

Hazard

  • Cracked, uneven or non-smooth floors can make trolleys harder to move by increasing pushing forces.

Risk control

  • Inspections and regular maintenance to keep floor surfaces clean, smooth and well maintained.

Hazard

  • Steep gradients on ramps increase the force needed to move trolleys.

Risk control

  • Ensure trolleys are handled on flat or low-gradient surfaces.

Hazard

  • Wet floors create risk of slipping.

Risk control

  • Ensure floor surfaces are suitable for wet areas.
  • Ensure all spills are cleaned up as soon as possible.

Housekeeping

Hazard

  • Dirty floors due to grease, residue, fats, oils, crumbs, etc. make it harder to move trolleys.

Risk control

  • Regular housekeeping to keep work areas clean and free of obstructions and trip hazards.

Maintenance

Hazard

  • Damaged trolleys and castors make moving trolleys difficult and increase the risk of an MSD.

Risk controls

  • Immediate removal for repair and replacement of damaged trolleys.
  • Implementation of a systematic preventative maintenance system for trolleys and castors.

The WorkSafe website has guidance about choosing and using trolleys.

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.

Related pages

This information is from 'Manual handling in the food manufacturing industry: A guide for employers'. The complete guide is available in two formats.

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