Handling bags of ingredients

Use solutions with the least risk

Employees often manually handle raw materials into hoppers, sieves, kettles and other processing plant. Handling materials into processing plant frequently requires feeding material from the floor or an elevated work platform. This task can become increasingly difficult because contents in the bags often shift. The shifting contents can make the bags unbalanced and difficult to hold.

The following solutions can help employers control risks to employees handling bags of ingredients in different situations. 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 bags of ingredients, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Handling bags from pallets on the ground

High-risk actions which can cause an MSD

• Using high force to lift and lower heavy loads.
• Lifting heavy loads in an awkward posture.

Potential source of risk

• Pallet is located on the ground.

Handling solutions

Preferred solutions with the least risk

• Replace bags with larger delivery systems such as bulk bags or intermediate bulk containers and use automated feeding devices such as bulk feeders, suction-feed devices or auger-feed silos.
• Use a vacuum lifter.
• Obtain pre-mixed ingredients.

Solutions with a reduced risk

• Use automated bag-emptying devices in combination with vacuum hoists or pallet lifters.
• Use height-adjustable pallet lifters fitted with a turntable.
• Provide a pallet stand or lifting aid to keep bags between knee and shoulder height.
• Use a two-person or team lift.

Handling bags from pallets on the ground, only one side is accessible

High-risk actions that can cause an MSD

• Using high force to lift and lower heavy loads.
• Lifting heavy loads in an awkward posture.

Potential source of risk

• Pallet is on the ground and only one side of the pallet is accessible.

Handling solutions

Preferred solutions with the least risk

• Replace bags with larger delivery systems such as bulk bags or intermediate bulk containers and use automated feeding devices such as bulk feeders, suction- feed devices or auger-feed silos.
• Use a vacuum lifter.
• Obtain pre-mixed ingredients.

Solutions with a reduced risk

• Provide access to all sides of the pallet by installing a pallet ring to rotate the pallet, allowing access from one location.
• Change orientation or position of the pallet to allow access from at least 2 sides.
• Use narrow pallets or a pallet-tilt mechanism to reduce reach distances.
• Use a two-person or team lift.

Note: These measures should be implemented in combination with a pallet lifter to keep the load between knee and shoulder height.

Restraining and opening bags against the processing plant

High-risk actions that can cause an MSD

• Using high force to lift and lower heavy loads.
• Lifting heavy loads in an awkward posture.

Potential source of risk

• Restraining a bag against the processing plant while opening the bag.

Handling solutions

Preferred solutions with the least risk

• Replace bags with larger delivery systems such as bulk bags or intermediate bulk containers and use automated feeding devices such as bulk feeders, suction-feed devices or auger-feed silos.
• Use a vacuum lifter.
• Obtain pre-mixed ingredients.

Solutions with a reduced risk

• Provide height-adjustable benches or a resting panel to sit bag on while opening.

Handling heavy bags of ingredients

High-risk actions that can cause an MSD

• Using high force to lift and lower heavy loads.
• Lifting heavy loads in an awkward posture.

Potential source of risk

• Weight of the bag.

Handling solutions

Preferred solutions with the least risk

• Replace bags with larger delivery systems such as bulk bags or intermediate bulk containers and use automated feeding devices such as bulk feeders, suction-feed devices or auger-feed silos.
• Use a vacuum lifter.
• Obtain pre-mixed ingredients.

Solutions with a reduced risk

• Buy lighter bags. Note: Using smaller or lighter bags may increase the frequency of handling and, depending on the circumstances, may not reduce the risk.

Tipping bags requires lifting above shoulder height

High-risk actions that can cause an MSD

• Using high force to lift and lower heavy loads.
• Lifting heavy loads in an awkward posture.

Potential source of risk

• Tip-in height requires lifting above shoulder height.

Handling solutions

Preferred solutions with the least risk

• Use an automated tipper.
• Replace bags with larger delivery systems such as bulk bags or intermediate bulk containers and use automated feeding devices such as bulk feeders, suction-feed devices or auger-feed silos.
• Use a vacuum lifter.
• Obtain pre-mixed ingredients.

Solutions with a reduced risk

• Provide a platform to raise the height of the employee.
• Provide a height-adjustable workbench or trolley to take the bag up to the required height.

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.