Manual handling in the red meat processing industry

Head removal of beef involves high force, often with the arms outstretched, increasing the horizontal distance to the lower back of the beef when trying to catch or hold the heavy load. The head is then transferred to another rail and this can involve the worker twisting their back.

Figure 1: Employee removing head.

High-risk activities that should not be used in the workplace

• Lifting, lowering or carrying the head without a support.
• Catching, holding or supporting the head without a support.
• Exerting force with the non-preferred hand.
• Exerting high force while in an awkward posture.

Potential source of risk that increase the risk of injury

• Standing position means the employee has to reach away from the body, above shoulder height or below mid-thigh height to sever, support and re-hang the head.
• The position of the head rail is distant to the main rail.
• The weight and size of the head.
• Wearing gloves and handling a slippery object.

Reduced-risk solutions

Provide mechanical aids to support the weight of the head if there is enough room to safely manoeuvre the aid.

• Use a height adjustable trolley to support the head after it is removed and to transport it to the production area for tongue and cheek removal. Ensure that the trolley is always sanitized.
• Position the automatic lifter close to the carcass. Use a hook attachment before the head is severed. This helps to ensure that the employee doesn’t need to catch and support the head.

Figure 2: Height adjustable trolley is used to support the head after it is removed and to transport it to the production area for tongue/cheek removal. The trolley must always be sanitised.

Figure 3: The lifter is positioned close to the carcass, with a hook attached before the head is severed, ensuring the employee doesn’t need to catch and support the head.

Low-risk solution

Implement engineering controls.

• With the main chain and head chain running parallel, the torso and head are separated and the hook bears the load.
• A head rail and hook used to support the weight of the head once it has been severed.
• The section of the rail shown is automatically raised to allow further processing of the head.
• For small stock, an automatic head remover can be used to sever the head without any manual handling.

Figure 4: The main chain and head chain are running parallel. The torso and head are separated and the hook bears the load.

Figure 5: Example of a head rail and hook used to support the weight of the head once it has been severed.

Figure 6: The section of the rail shown is automatically raised to allow further processing of the head.

Figure 7: For small stock a mechanical aid can be used to sever the head without any manual handling.

Pelting mutton is a staged process largely controlled by mechanical hide pullers. Where parts of these tasks are performed manually, this 'punching' down involves repetitive awkward postures, high forces, grabbing, pulling and other movements that can result in MSDs.

Figure 8: Punching down before pelt removal.

High-risk activities that should not be used in the workplace

Bending the back forwards more than 20 degrees, twisting the back more than 20 degrees, exerting force while in an awkward posture:

• repetitively: more than twice per minute; and/or
• with long duration, more than 30 minutes continuously or more than 2 hours over the whole shift

These actions may occur in the situations listed under 'potential source of risk' or in combination with other work activities.

Exerting high force while in an awkward posture.

Potential source of risk that increase the risk of injury

• The nature of the load.
• The height of the task.

Reduced-risk solution

Use rails to present task at heights that reduce the need to bend and reach.

Provide training in the use of mechanical aids such as pelting arms to assist with the task.

Figure 9: Training in the use of mechanical aids such as pelting arms to assist with the task.

Low-risk solution

Use mechanical hide pullers to eliminate the manual handling.

Figure 10: A mechanical hide puller is used to eliminate the manual handling in this part of the task.

Figure 11: Working with product tubs at ground level.

Pushing and pulling tubs of product at ground level requires employees to forward bend their backs and exert force in awkward postures. The force required to push and pull trolleys or bins can be influenced by the floor surface and the size of the trolley wheels, as well as by other variables.

Handling tubs of product over wet floor surfaces introduces the added risks of slipping and falling which can also result in MSDs.

High-risk activities that should not be used in the workplace

Exerting high force while in an awkward posture. Pushing and pulling objects that are hard to move or stop.

Potential source of risk

• The weight of the tubs or trolley.
• Slippery floor or surface.

Reduced-risk solution

Use mechanical aids such as trolleys to keep loads at heights that eliminate or reduce the need to bend.

• A purpose built trolley bin can be used to collect viscera (gut content) (Figure 12).
• Tipping the heavy offal bin can be made easier with handles on the bin and the receptacle below floor height eliminating the need to lift. Use a system to collect off-cuts from the hanging carcass (Figure 14) and a trolley to transfer the off-cuts for further processing. For example, use a trough on a slope to collect off-cuts.
• A trolley can be used to raise the height of the tub to an appropriate working height.

Figure 12: A purpose built trolley bin is used to collect viscera (gut content).

Figure 13: Tipping the heavy offal bin is made easier with handles on the bin and the receptacle below floor height eliminating the need to lift. Edge protection would be required for a drop greater than 2 metres.

Use a system to collect off-cuts from the hanging carcass and a trolley to transfer the off-cuts for further processing.

Figure 14: The trough collects off-cuts and is sloped to help transfer the off-cuts to a transfer trolley.

Figure 15: A well-designed trolley is used to raise the height of the white tub.

Reduce the amounts carried in the tub or container to reduce the force required to move the load.

Improve trolley design by changing the diameter of the wheels.

Choosing and using trolleys

Low-risk solution

Where practicable, eliminate hazardous manual handling by using floor chutes and conveyors.

Figure 16: For employees working on an evisceration conveyor, the conveyor transfers the gut contents eliminating the need for handling trolleys or tubs.

Use a mechanical aid to raise and tip offal bins.

Figure 17: A trolley bin elevator and tipper.

Figure 18: Use floor chutes to reduce the carrying distance when disposing of tubs of waste from the kill floor.

Pushing carcasses requires high force exertion in awkward postures and usually in environments where temperatures are too cold for prolonged manual handling activity if the employee is not wearing additional layers of clothing.

Often there is also the risk of falls, with blood and ice making the floor slippery. High push forces and the lack of slip resistance increases the likelihood of this risk.

Figure 19: Pushing carcasses requires the application of high force.

High-risk activities that should not be used in the workplace

Pushing and pulling objects that are hard to move or stop requires high force while in an awkward posture.

Potential source of risk that increase the risk of injury

• Weight of carcasses.
• Condition or maintenance of overhead rails.

Reduced-risk solution

• Maintain overhead rail systems and hooks.
• Establish a set limit on the maximum number of sides in the workplace to be handled by employees at a time. For example, a limit of 2 sides of one carcass enables a push without excessive force (Figure 20). Train employees on this and ensure it is enforced.

Figure 20: A limit of 2 sides of one carcass enables a push without excessive force.

Low-risk solution

• Where possible, install gravity rails at very small gradients. It is important and necessary to assess the risks associated with a moving carcass striking someone.
• Use low resistance plastic hooks to reduce push forces (Figure 21).

Figure 21: Low resistance plastic hooks used with mutton.

Boning is associated with a high rate of MSDs — particularly of the wrist and arms.

Boning is very repetitive. It can require the application of high force, particularly if the knife has become blunt or if the meat contains hard fat or is at a low temperature.

Figure 22: Cutting too low at a side chain means there is repeated and sustained back bending.

High-risk activities that should not be used in the workplace

Bending the back forwards more than 20 degrees, and exerting force while in an awkward posture:

• respectively: more than twice per minute;
• in a sustained way: more than 30 seconds at a time; and/or
• with long duration: more than 30 minutes continuously or more than 2 hours over the whole shift.

These actions may occur in the situations listed under Potential source of risk or in combination with other work activities.

Potential source of risk

• Boning tables too high or too low for the individual.
• Height of the cut on the side chain too high or too low for the individual.

Reduced-risk solution

• Provide height adjustable workstations, train employees in how to use them and supervise their correct use.
• Provide adjustable stands to better match working heights of individuals.

Figure 23: Adjustable stands better match the different heights of individuals.

Figure 24: A simple mechanism to adjust working height.

Use platforms to raise the height of the employees for the various stages of the cut.

Figure 25: Platforms are used to raise the height of the employees for the various stages of the cut on this side chain.

Low-risk solution

• Meat tensioning equipment is one example of a mechanical aid to assist the manual handling involved in boning.
• Use boning technology that allows the employee to complete the work in a comfortable and natural upright posture as much as reasonably practicable.

Figure 26: The employee is able to work close to his body, with an upright posture, where the cutting is done mainly between the waist and shoulder height.

Figure 27: Machine pulling the meat away from the bone, allowing more natural back and shoulder postures.

High-risk activities that should not be used in the workplace

Excessive bending of the wrist, exerting high force with one hand, twisting and turning actions with the hands and arms and sustained holding of a tool, knife and or meat hook:

• repetitively: more than twice per minute;
• in a sustained way: more than 30 seconds at a time; and/or
• with long duration: more than 30 minutes continuously or more than 2 hours over the whole shift.

Potential source of risk

• Using a knife that is not sharp enough.
• Hard fat increasing the force to cut the meat.
• Chilled carcasses increasing the force required to cut the meat.
• Holding hook to pull meat from bone.

Reduced-risk solution

Ensure an effective knife sharpening program is implemented including competency-based training in the selection, use and sharpening of knives, so far as is reasonably practicable.

Ensure carcass is at the correct temperature for boning, especially after extended time periods in chillers, such as weekends.

Low-risk solution

• Use technology that assists in the boning process.
• Together with a sharp knife, use a mechanical aid such as meat tensioning equipment to pull the meat away from the bone, reducing awkward wrist postures of the cutting hand. (Figures 26, 27 and 28).

Figure 28: Meat is mechanically pulled away from the bone, reducing awkward wrist postures of the cutting hand.

Figure 29: Workstation is too high, requiring the need for awkward postures such as raised shoulders.

When employees work for prolonged periods of time at fixed workstations or next to conveyors, it is important that each workstation is adjusted for each employee. Correctly adjusted workstations reduce the risk of MSD and improve productivity.

Wrapping and packing can involve awkward postures, such as raised shoulders, and repeated actions such as reaching to pick up cuts of meat or twisting the body while handling loads.

High-risk activities that should not be used in the workplace

Exerting force while in an awkward posture:

• repetitively: more than twice per minute;
• in a sustained way: more than 30 seconds at a time; and/or
• with long duration more than 30 minutes continuously or more than 2 hours over the whole shift.

These actions may occur in the situations listed under Potential source of risk or in combination with other work activities.

Potential source of risk

• The height of the workstation does not 'fit' the individual.
• The position of the product forces the employee to reach.

Reduced-risk solution

• Provide workstations that can be adjusted for tasks and people.
• Design tasks and workstations to reduce unneeded movements and awkward postures so far as is reasonably practicable. Good design can eliminate hazardous manual handling while also increasing productivity.
• Manual tasks should be done below a person’s standing elbow height.
• Use a system of conveyors to allow the meat cuts to be easily pulled into the box. The box can then pushed onto the exit conveyor with minimum effort.
• Use a turntable to reach objects to eliminate forward reaching by the employee (Figure 32).

Figure 30: Use a system of conveyors to allow the meat cuts to be easily pulled into the box. The box is then pushed onto the exit conveyor with minimum effort.

Figure 31: The design of the task allows the employee to pack boxes in a relaxed upright posture.

Figure 32: This turntable presents objects to eliminate forward reaching by the employee.

Low-risk solution

• Use equipment that eliminates hazardous manual handling.
• Mechanised wrapping equipment can eliminate repetitive handling from some tasks (Figure 33).

Figure 33: Cuts of meat are wrapped automatically, eliminating a repetitive handling task.

Figure 34: Forward bending, reaching and twisting to lift out meat product can result in MSDs.

Large stillages or containers are used to transfer product between processes within a plant. These stillages are normally manufactured to a standard pallet design and stand up to 100 cm high.

Forward bending, reaching and twisting to lift out meat product can result in MSDs.

High-risk activities that should not be used in the workplace

Bending the back forwards or sideways more than 20 degrees, twisting the back more than 20 degrees:

• repetitively: more than twice per minute;
• in a sustained way: more than 30 seconds at a time; and/or
• with long duration: more than 30 minutes continuously or more than 2 hours over the whole shift.

These actions may occur in the situations listed under Potential source of risk or in combination with other work activities.

Potential source of risk

A stillage or container at ground level.

Reduced-risk solution

Use a purpose-built stillage lifter and tipper with a tool to reduce the need for reaching and bending.

Use stillages with drop down sides in combination with a pallet lifter to minimise forward back bending and reaching.

Figure 35: A stillage lifter and tipper with a tool to reduce the need for reaching and bending.

Figure 36: Employee packing into a raised stillage with side access, minimising forward back bending and reaching.

Low-risk solution

Use mechanical aids such as vacuum lifters where the product is already bagged.

Figure 37: Employee using a vacuum lifter to handle the bagged meat from the stillage.

Figure 38: Employee applying high force to shift a heavy shelf in a cold room.

Handling boxed meat up to 33 kg in and out of blast freezer frames or racks is a repetitive task which involves high force. Often the task is done in very cold environments. Hazardous manual handling like this is very likely to result in MSD.

Mechanical aids that can replace forklifts in work areas are available. If forklifts are introduced into areas where employees are working, a traffic management plan needs to be implemented to separate employees from forklifts.

High-risk activities that should not be used in the workplace

Bending the back forwards more than 20 degrees, lifting and lowering and exerting high force while in an awkward posture:

• repetitively: more than twice per minute; and/or
• with long duration: more than 30 minutes continuously or more than 2 hours over the whole shift.

These actions may occur in the situations listed under Potential source of risk or in combination with other work activities.

Potential source of risk

The opening within the freezer frame which is located below mid-thigh height.

Handling boxed meat that can weigh up to 33 kg.

Working in or adjacent to areas of low temperature. For example, up to minus 10 degrees Celsius.

Reduced-risk solution

Provide height adjustable lifters that raise the lower rows of the freezer frames so boxes are handled without the need to forward bend the back. For example, use a scissor type lifter to raise the lower levels of the freezer rack (Figure 39). Aim to have this handling done at about waist height to reduce risk.

Raise freezer frames using a pedestrian operated forklift truck to suitable working height to reduce back bending.

Figure 39: A blast freezer rack is raised using a portable scissor type lifter.

Figure 40: Handling a box of meat at waist height by raising the freezer frame using a pedestrian operated forklift truck.

Low-risk solution

Where practicable, consider reducing the weight of boxed products.

Install mechanical aids to eliminate the repetitive manual handling of heavy loads.

Introduce a box handling system that eliminates manual handling of boxed meat.

Figure 41: Boxed meat can be automatically conveyed to a plate freezer system.

Install a pallet inverter using spacers with thermal properties between the layers of boxes to eliminate double handling of frames from freezer to pallets.

Figure 42: The first image shows employee with a pallet inverter as he tilts back the boxes to remove the spacers in preparation for slip sheeting the pallet. The second image shows a pallet inverter using spacers with thermal properties between the layers of boxes to eliminate double handling of frames from freezer to pallets.

High-risk activities that should not be used in the workplace

Working with one or both hands above shoulder height and exerting high force while in an awkward posture:

• repetitively: more than twice per minute; and/or
• with long duration, more than 30 minutes continuously or more than 2 hours over the whole shift.

These actions may occur in the situations listed under Potential source of risk or in combination with other work activities.

Potential source of risk

The opening in the freezer frame rack is located above shoulder height.

Handling boxed meat that can weigh up to 33 kg.

Reduced-risk solution

• Use mechanical aids to eliminate the need to handle boxes above shoulder height (Figure 43).
• Use height adjustable equipment in combination with a sunken dock and fall protection.
• Reduce the height of freezer frames so the top levels are not above shoulder height.
• Prevent the use of the top layers of the freezer frames which are above shoulder height. One way to achieve this is by covering up the openings.
• Raise the employees' working level where there is no sunken dock by using a purpose-built platform.

Figure 43: Height adjustable mechanical aid eliminating need to handle boxes above shoulder height. Note: the guarding has been temporarily removed in order to illustrate this.

Figure 44: A employee removing spacer laying sheets that allow air flow for freezing.

Low-risk solution

Use a box handling system (figures 43 and 44) that eliminates the need to use freezer frames. This solution may not be practicable for every product.

Figure 45: Palletising involves bending, reaching and twisting movements.

Most industries use pallets to pack and store product.

Palletising involves bending, reaching and twisting movements. The risks of MSDs to employees are known to increase when awkward movements are combined with handling heavy loads, sometimes up to 33 kg.

When forklifts move pallets in areas where people work, a traffic management plan needs to be implemented to ensure pedestrians and forklifts are separated.

Developing a forklift traffic management plan

High-risk activities that should not be used in the workplace

Bending the back forwards or sideways more than 20 degrees, twisting the back more than 20 degrees, lifting and lowering and exerting force while in an awkward posture:

• repetitively: more than twice per minute; and/or
• with long duration more than 30 minutes continuously or more than 2 hours over the whole shift.

These actions may occur in the situations listed under Potential source of risk or in combination with other work activities.

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

Potential source of risk

Pallets at ground level.

Reduced-risk solution

Use pallet lifters.

Figure 46: Pallet lifters at the end of conveyor lines.

Figure 47: Pallet lifters with turntables alongside a conveyor.

Figure 48: Employee using a pallet lifter with turntable to reduce forward bending and reaching.

Low-risk solution

Use engineering controls. For example, a robot palletiser and a vacuum lifter.

Use a vacuum lifting device to eliminate the carrying force.

Figure 49: A robot palletises boxes from a conveyor system. Interlocks and guarding ensure this is a pedestrian free area.

Figure 50: A vacuum lifter to transfer a box from a conveyor to a pallet.

Figure 51: Stretch-wrapping pallets manually, requires poor postures and movements and often high force.

Stretch-wrapping pallets manually, requires poor postures and movements and often high force. Most manufacturers have moved to automatic or semi-automatic units.

High-risk activities that should not be used in the workplace

Bending the back and/or neck forwards more than 20 degrees and exerting high force in an awkward posture:

• repetitively: more than twice per minute;
• in a sustained period: more than 30 seconds at a time; and/or
• with long duration: more than 30 minutes continuously or more than 2 hours over the whole shift.

These actions may occur in the situations listed under Potential source of risk or in combination with other work activities.

Potential source of risk

Pallets at ground level.

Wrap requires being stretched using force.

Reduced-risk solution

Improve postures and movements by manually stretch-wrapping pallet on a raised automated scissor lift and turntable.

Only manually stretch-wrap at above mid-thigh height.

Use an alternative packing product such as tape-wrapping.

Low-risk solution

Install and use an automated stretch-wrapper.

Figure 52: An automated stretch-wrapper eliminates the manual task.

Use a semi-automatic stretch-wrapping machine.

Use a vacuum-sealing or shrink-wrapping device to wrap pallets.

Figure 53: Stacking boxed meat above shoulder height.

Loading shipping containers with boxes of meat that can weigh up to 33 kg is a repetitive task involving high force and awkward postures.

Forward bending and reaching to pick up boxes from pallets at floor height or above shoulder height when stacking to the roof are common causes of MSDs.

Loading containers manually is hazardous and involves substantial risk of MSDs if not appropriately controlled.

High-risk activities that should not be used in the workplace

Forward bending the back and/or neck more than 20 degrees and twisting, turning, pushing, pulling or dragging:

• repetitively: more than twice per minute; and/or
• with long duration: more than 30 minutes continuously or more than 2 hours over the whole shift.

These actions may occur in the situations listed under Potential source of risk or in combination with other work activities.

Exerting high force while in an awkward posture.

Potential source of risk

The position of the load at pick up and at placement.

The weight of the load, for example, export beef can weigh up to 33 kg.

Reduced-risk solution

Use mechanical aids, including load shifting equipment, conveyor belts and pallet filters.

Use pallet jacks wherever possible.

Use conveyor belts to deliver boxes at waist height inside the container.

Use pallet lifters with turntables inside the rear of the container. This will present boxes at waist height and reduce reach distances.

Ensure employees are trained and skilled in loading techniques, including stacking, in a way that minimises above shoulder height handling.

Low-risk solution

Automate the process to eliminate any manual handling.

Use forklifts and slip-sheets.

Figure 54: A pallet load of product is mechanically pushed into position using a slip-sheet and forklift.

Wooden pallets are a common method for moving product and material.

Handling empty pallets manually requires high force, poor postures and movements and often results in injury.

Lower limb injuries can occur if a pallet is dropped.

Figure 55: Employee manually handling pallet.

High-risk activities that should not be used in the workplace

Exerting high force while in an awkward posture.

Potential source of risk

Moving pallets from ground level.

The size of pallets.

The weight of pallets can be up to 35 kg.

Reduced-risk solution

Use hand pallet jacks.

Use lighter weight plastic pallets.

Use a hook to tilt lighter weight pallets so that they are vertical. This reduces bending the back forward with the load.

Always ensure a 2-person lift if pallets must be manually handled.

Low-risk solution

Install a mechanical pallet stacker.

Figure 56: The mechanical pallet stacker eliminates the manual task of handling and stacking empty pallets.

Use forklifts or other mechanical aids such as a wide straddle pallet mover and lifter.

Figure 57: Manual load out and lumping involves the use of high force and awkward postures.

Loading out into trucks and lumping carcasses into customers’ premises involve hazardous manual handling due to the high forces and awkward postures involved in handling heavy loads.

When completing these tasks employees may also slip, trip or fall. There is a high incidence of MSD to the back, shoulders, neck and arms related to this task, particularly with lumping.

High-risk activities that should not be used in the workplace

Using high force to lift, lower and carry heavy loads.

Using high force while in an awkward posture.

Jumping while holding a load.

Potential source of risk

The position of the load.

The weight of the load. For example, a pig carcass can weigh up to 60 kg.

The distance and terrain. For example, steps from trucks, street gutters in darkness, stairs, long corridors in shopping centres.

Reduced-risk solution

• Identify the types of hazards at the customer’s premises and respond with practical controls.
• Use mechanical aids such as links between rails and trucks at load out to eliminate unnecessary extra handling.

Figure 58: A link rail between a truck and load out rail.

Use diverters within trucks to eliminate the double handling required with cross-rail trucks.

Figure 59: An employee can push carcasses onto different rails inside the truck or chiller without needing to double handle them across rails.

Figure 60: customer’s rail doesn’t link with the truck rail but does eliminate the lumping involved when stepping down from the truck and carrying the carcass into the shop.

In some instances it may be possible to break down a carcass in the truck to reduce the overall load and weight.

Low-risk solution

• Deliver boxed meat wherever reasonably practicable (This will depend on customer demand).
• Use a combination of delivery approaches such as a mix of carcase and boxed meat product.
• Rail systems at customer's premises can be linked to the rail system of the truck to eliminate lumping wherever reasonably practicable.

Figure 61: The rail system at the customer's premises is connected to the delivery truck (not shown). This reduces most of the hazardous manual handling such as the lifting and carrying of carcasses.

Trolleys with powered tugs can be used for some customer premises. This reduces most of the hazardous manual handling such as the carrying of carcasses.

Figure 62: A trolley with rails is linked to the truck to eliminate the need to lift carcasses. The trolley is then pulled with a powered tug to where it reconnects with rails within the customer's premises.