Palletising product

Use solutions with the least risk

Most industries require the palletising of product. Frequently this process involves bending and twisting when transferring product from racks, trolleys or the production line. Introducing pallet lifters can sometimes raise the height of the product so high that product is required to be placed above shoulder height, which may increase the risk of injury. Most pallet lifters also require mechanical aids to place and remove pallets. There are mechanical aids available that can replace forklifts in work areas.

If forklifts are introduced to move pallets into areas where people work, a traffic management plan needs to be implemented to ensure the separation of pedestrians and forklifts. WorkSafe has guidance to help with the development of a forklift traffic-management plan. Forklift operators must be licensed.

The following solutions can help employers control risks to employees transferring products to pallets. 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 pallets, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Working from pallets on the ground

High-risk actions that can cause an MSD

• Bending and twisting the back more than 20 degrees, 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.

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

Potential source of risk

• Pallets of goods on the ground.

Handling solutions

Preferred solutions with the least risk

• Automate the process.
• Use a vacuum lifting device.

Solutions with a reduced risk

• Ensure that empty pallets are placed under the pallet being filled to keep handling between mid-thigh and shoulder height.
  • This requires a mechanical aid such as a walkie-stacker or straddle-lifter to raise or adjust the height of the working pallet.

Placing and receiving products from a pallet lifter

High-risk actions that can cause an MSD

• Working with one or both hands above shoulder height 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.
• Exerting high force while in an awkward posture.

Potential source of risk

• Introduction of a pallet lifter raises the height of product for placing and retrieving above shoulder height.

Handling solutions

Preferred solutions with the least risk

• Automate the process.
• Use a vacuum lifting device.

Solutions with a reduced risk

• Reduce the height of product on the pallet by eliminating one or more layers.
• Introduce a purpose-built platform area or provide mobile steps and a platform to bring the employee up to the appropriate height.
  • If using steps while carrying product creates a hazard, transfer product using mechanical aids.
• Introduce low-profile lifters that do not raise the pallet as high. Ramps can also be used with low-profile lifters to allow the use of pallet jacks.
• Recess the pallet lifter into the floor.

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.