Health and safety issues on the production line can cause major damage to your bottom line. Workplace injuries don’t just lead to increased paperwork and human resource challenges – they also disrupt the efficiency of your entire processing plant.
Accidents can result in missed deadlines, reduced output, and strained operations. Moreover, injuries can expose your business to potential legal liabilities, including costly workers’ compensation claims and compliance violations, which can further strain your financial resources and damage your company’s reputation.
Mechanical handling equipment is key to helping to improve worker safety and workflow efficiency. However, in the same way as there are manual handling hazards, there are also mechanical handling hazards. Read on to learn what they are and how to avoid them.
Overview:
- What is a manual handling risk?
- Percentage of workplace injuries caused by manual handling
- Mechanical handling hazards
- Avoiding mechanical handling hazards
What is a manual handling risk?
A manual handling risk refers to the prospect of injury due to any sort of manual handling of materials, most commonly lifting or moving. You can also think of manual handling risks as being associated with “push, pull, carry” actions.
To avoid manual handling risks, processors use mechanical handling equipment or material handling equipment. Examples of mechanical handling equipment include conveyors, lifting devices, turntables etc.
Learn more: Mechanical handling equipment examples
What percentage of workplace injuries are caused by manual handling?
24% of workplace injuries were caused by activities related to manual handling, such as lifting, pushing, pulling, or bending. Of those affected, 66% required time off to recover from their injuries, and 31% received compensation as a result. These statistics highlight the significant impact of manual handling injuries on both workers and businesses, reinforcing the need for proper training and equipment to reduce risks.
Three mechanical handling hazards in food processing
While mechanical handling equipment in food processing enables us to avoid manual handling injuries, there are still hazards associated with mechanical handling that need to be considered.
1. Moving parts or sharp edges of mechanical handling equipment
Mechanical handling equipment is designed to enhance efficiency and safety, however there are risks if the proper work instructions and safety equipment are not used as directed. In a busy production environment, workers may become distracted and be injured by moving equipment, especially if visibility is limited or the equipment operates autonomously.
Clear warning systems, proper barriers, or restricted zones, can help to prevent injuries or damage in the factory or warehouse. Organisations have a responsibility to ensure that proper machine guarding and Personal Protective Equipment (PPE) is in use to meet occupational health and safety requirements.
2. The equipment’s load
Another hazard associated with mechanical handling equipment is the load it bears. While machines are designed to handle heavy or awkwardly shaped materials, an unstable or unsafe load still presents a hazard.
An unstable load, caused by improper packing or stacking or even hazardous material contents, may shift during transport, leading to spillage, falling objects, or machine malfunction. These incidents can endanger workers operating nearby, and may cause serious injuries such as crushing, lacerations, or fractures.
For example, a poorly balanced pallet or improperly secured crates can topple over, harming workers and damaging equipment.
3. Human error & improper training
If workers aren’t properly trained in the use of the equipment, this poses a very real hazard. Common training errors include:
- Loading the machine and equipment above its safe working load/capacity
- Not using the proper equipment for the size and shape of the material being moved
- Operating the equipment in areas it’s not designed for
- Failing to take precautions when stacking materials
- Using the equipment for another purpose other than its intended
- Avoiding mechanical handling hazards
How to avoid mechanical handling hazards
- Planning: Take the time to evaluate the space that will house the equipment and how the workflow will move in and around that space. Other control measures include maintaining walking/working surfaces to prevent slips, trips, and falls, machine guarding, and ergonomics programs.
- Load calculation: In order to make the most efficient use of your mechanical handling equipment, we advise you to consider current and ideal through-put. Choosing the right mechanical handling equipment for the anticipated loads and allowing a buffer for growth will help keep workers safe.
- Training: To reduce the risk of human error, it’s essential to provide training to operators and other members of staff working in the vicinity of the equipment. FPE provides comprehensive on-site training with any machinery we supply.
- Regular maintenance: Mechanical handling equipment is only as good as its last service. It’s of paramount importance, both to your bottom line and the safety of your employees, that you schedule regular maintenance of your machines and even invest in spare parts supply.
Learn more: Importance of spare parts in the food processing industry
We can help select the right mechanical handling equipment and train staff in safe and effective use
At FPE, we are proud suppliers of SYSPAL mechanical and bulk material handling equipment in Australia and New Zealand.
Whether you’re looking to improve efficiency, enhance safety, or upgrade your production line with state-of-the-art handling solutions, we’re here to help. Our comprehensive range of SYSPAL products is designed to meet the unique needs of the food processing industry, offering innovative solutions for lifting, conveying, and handling materials with ease and precision.
Contact us today to find out more about the mechanical handling solutions and comprehensive customer support we provide.
Mechanical Handling Hazards: FAQs
What are the most common mechanical handling hazards in food processing?
The most common mechanical handling hazards include injuries caused by the equipment itself, such as trapping or catching body parts, collisions with machinery, and unsafe or unstable loads. Improper training can also lead to significant risks, such as overloading equipment or using it incorrectly.
How can mechanical handling hazards be prevented?
Mechanical handling hazards can be avoided by proper planning, ensuring load calculations are accurate, providing thorough training to operators, and maintaining equipment through regular servicing. Machine guarding and using appropriate personal protective equipment (PPE) are also critical measures.
Why is regular maintenance important for mechanical handling equipment?
Regular maintenance is crucial to ensuring mechanical handling equipment operates safely and efficiently. It helps prevent breakdowns, reduces the risk of workplace accidents, and ensures that the equipment continues to meet safety standards, ultimately protecting both employees and productivity.
