Ergonomic Lifting Solutions: Reduce Workplace Injuries in Food & Beverage Manufacturing
In the fast-paced food and beverage industry, employee safety is just as critical as production output. For safety managers, the challenge is clear: how do you reduce injuries without slowing down production? The answer lies in ergonomic lifting solutions.
Every day, workers face high-risk manual handling tasks such as; lifting heavy crates of ingredients, unloading shipping containers, or moving bulky packages. Without proper safeguards, these tasks can lead to serious workplace injuries, lost productivity, and higher costs.
Why Workplace Injuries Are So Common in Food & Beverage Manufacturing
Manual handling is one of the leading causes of musculoskeletal disorders (MSDs) and workplace accidents. HSE statistic highlights that manual handling accounts for around 20 % of all workplace injuries in the UK.
Common injury risks include:
- Stacking/unstacking containers (boxes, crates, sacks).
- Pushing wheeled racks (oven racks, trolleys).
- Handling drink containers (casks, kegs, crates).
- Packing products (cheese, confectionery, biscuits).
- Meat & poultry processing (cutting, boning, trussing, evisceration).
These repetitive, high-strain activities often result in back injuries, sprains, and work-related upper limb disorders (WRULDs). The cost of a single injury can be substantial—not just medical expenses, but also downtime, replacement staffing, and long-term absenteeism.
The Limitations of Manual Lifting & Training Alone
Even with proper training, workers get fatigued, shortcuts happen, and lifting technique breaks down over time. Injuries occur when repetitive strain and poor posture catch up with workers. Safety training is essential, but on its own, it cannot remove the root cause: the physical strain of lifting.
What Are Ergonomic Lifting Solutions?
Ergonomic lifting solutions are mechanical tools designed to remove the physical strain from manual handling. They include:
- Vacuum lifters for sacks, boxes, and crates.
- Reel lifters for packaging rolls.
- Lifting trolleys and hoists for flexible handling.
- Container unloaders for safe unloading of boxes and sacks.
By aligning with natural human movements, these systems protect workers from overexertion while maintaining speed and efficiency in production. Even the UK Health & Safety Executive recommends “full mechanical handling” wherever possible, including vacuum lift-assisted palletisers and conveyors.
Why Vacuum Lifters & Smart Lifting Are the Safer Choice
Here’s how vacuum lifters and other ergonomic material handling equipment outperform manual lifting:
- Heavy Weight Handling
Challenge: Manual lifting of 25–32 kg (55–70 lbs) sacks poses ongoing risks.
Solution: Vacuum lifters eliminate the need for workers to bear weight, reducing fatigue and injury. - Reduced Unit Load Strain
Challenge: Handling smaller loads more frequently increases safety but can feel inefficient.
Solution: High-speed lifters maintain throughput without overloading staff. - Safe Stacking Heights
Challenge: Overhead lifting puts strain on shoulders and backs.
Solution: Vacuum lifters keep loads at safe ergonomic heights. - Container Unloading Made Simple
Challenge: Shipping container unloading is cramped and risky.
Solution: TAWI container unloaders tilt loads onto conveyors, no manual lifting required. - Reel Handling Without Strain
Challenge: Packaging reels are heavy and awkward.
Solution: Reel lifting trolleys allow safe lifting, tilting, and loading onto machines or racks.
Benefits of Ergonomic Lifting Solutions
- Injury Prevention: Reduce costly back injuries, strains, and sprains.
- Higher Productivity: Employees work faster and longer without fatigue.
- Better Compliance: Meet industry safety and sanitation requirements.
- Improved Morale & Retention: Workers feel valued, safe, and supported.
- Lower Costs: Fewer injuries mean reduced downtime, claims, and turnover.
Case Study: Kavli’s Soft Cheese Production
At Kavli’s cheese facility near Stockholm, operators used to manually lift 10–20 kg cheese blocks. Totalling 10 to 16 tons per day, day in and day out. The consequence? Fatigue, strain injuries, and mounting risk of long-term musculoskeletal damage.
By installing TAWI stainless-steel vacuum lifters with food-grade suction cups—mounted on overhead rails and designed for fast, hygienic cleaning—the facility transformed operations. After a decade of daily use, Kavli reports:
- Lower sick leave
- A notably easier and safer lifting process
- Operators describe the work as “far less physically intense,” making huge impact on productivity and team morale
How to Successfully Implement Ergonomic Lifting
- Assess Risks – Identify high-strain manual handling tasks.
- Choose the Right Solution – Match equipment to load type, weight, and workflow.
- Train Employees – Ensure staff are confident and competent using new equipment.
- Monitor & Improve – Gather feedback and refine processes.
At TAWI, we provide not only the right equipment but also on-site training and long-term service. We see every project as a partnership—tailoring solutions to your specific safety and productivity goals.
Building a Culture of Safety & Productivity
Investing in ergonomic lifting solutions sends a clear message: employee well-being and operational performance go hand in hand. For safety managers, it means fewer injuries “on your watch,” higher trust from production managers, and a workplace culture built on safety, efficiency, and care.