Handling empty bottles, jars or containers

Use solutions with the least risk

Removing empty bottles, jars and containers from pallets and placing them on to processing lines can involve repetitive bending with twisting and repetitive hand, finger and thumb grasping.

The following solutions can help employers control risks to employees handling empty bottles, jars or containers 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 empty bottles, jars and containers, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Removing bottles, jars and containers from pallets on the ground

High-risk actions that can cause an MSD

• Back bending and twisting:
  • 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.

Potential source of risk

• Pallet is located on the ground.

Handling solutions

Preferred solutions with the least risk

• Fully automate.
• Use a hoist.

Solutions with a reduced risk

• Provide a height-adjustable pallet lifter fitted with a turning ring to keep the load at a constant height.
• Provide a pallet stand to keep bottles between mid-thigh and shoulder height.
• Job rotation in combination with other risk controls that improve posture and movement.

  Note: Job rotation does not eliminate manual handling hazards. WorkSafe has guidance to help eliminate or reduce the health and safety risks associated with job rotation.

Removing bottles, jars and containers from pallets on the ground, only one side accessible

High-risk actions that can cause an MSD

• Forward back bending, reaching and twisting:
  • 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.

Potential source of risk

• Pallet is on the ground and only one side of the pallet is accessible forcing reach or increasing reach distances.

Handling solutions

Preferred solutions with the least risk

• Fully automate
• Use a hoist

Solutions with a reduced risk

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

  Note: These measures should be provided in combination with a pallet-lifter, keeping the load between mid-thigh and shoulder height.

• Job rotation in combination with other risk controls that improve posture and movement.

  Note: Job rotation does not eliminate manual handling hazards. WorkSafe has guidance to help eliminate or reduce the health and safety risks associated with job rotation.

Manually placing bottles and jars

High-risk actions that can cause an MSD

• Gripping and working with the fingers close together and/or wide apart 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.

Potential source of risk

• Manual placement of bottles and jars.

Handling solutions

Preferred solutions with the least risk

• Fully automate.
• Use a hoist.

Solutions with a reduced risk

• Change packaging to transfer containers in bulk.
• Implement job rotation in combination with other risk controls to reduce exposure to repetitive hand grasping.

  Note: Job rotation does not eliminate manual handling hazards. WorkSafe has guidance to help eliminate or reduce the health and safety risks associated with job rotation.

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.