Improve Ergonomics & Safety with Packaging Automation Solutions

Packaging facilities often operate at speed. These operations involve moving packaging and labelling materials quickly and constantly. Workers repeat physical tasks that place pressure on their bodies. Physical strains build gradually – sometimes without workers even realising the damage until later. 

In fact, musculoskeletal disorders appear more often in packaging work than in many other industrial settings. Handling cartons, rolls, pallets or sheets exposes workers to frequent risk. Back strain, shoulder pain, wrist issues or general fatigue that can become long-lasting.  

Injuries affect health, but poor material handling safety can affect the entire facility. As a result, productivity drops, absences increase, and insurance claims increase. This leads to losses in ROI for the packaging facility. 

 

Why Packaging Workflows Are High Risk for Operators 

Packaging lines bring together several difficult conditions at once. Heavy materials and tight spaces can be tough on the body. Repetitive tasks and quick movements add to this strain.  

No single factor is usually responsible. Instead, issues build quietly across a whole shift and sometimes across many months. 

Handling Heavy and Awkward Materials 

Many of the materials used in packaging and labelling are not shaped or weighted for easy handling. Film rolls can reach 80 kg or more. Stacks of cartons may shift when lifted. Pallets require workers to reach high or bend low, sometimes repeatedly. Even when workers use good judgment, the reality of these loads makes manual handling difficult. 

The European Agency for Safety and Health at Work advises that workers should not lift loads above 25 kg for men and 16 kg for women. Handling more weight exceeds recommended ergonomic limits in many situations. Packaging environments often ask workers to lift items far heavier than this. They may do this several times per hour, which increases the risk of strain. 

Repetitive Movements Throughout Shifts 

Many tasks in packaging become repetitive by nature. Folding cartons, lifting boxes, placing rolls into machines, or sealing packages all require similar movements and get repeated.  

Even a small movement can have a big impact. Doing it many times changes how the body reacts, which is why material handling safety is very important.   

Researchers examined 40 packaging workers over a three-month period in a food manufacturing facility. In the study, they used Rapid Upper Limb Assessment to evaluate posture and strain. They found that 25% of workers in operating and folding units were exposed to medium ergonomic risk. 

- Journal of Engineering Studies and Research, Volume 26 (2020) 

Further data from the same assessment, it was revealed that the following were at high ergonomic risk: 

• 30% of packing workers 
• 10% of carton wrapping workers 
• 10% of palletising workers faced very high risk requiring immediate changes 

These findings show how repetition gradually builds into significant strain across entire teams. 

Constrained Postures and Limited Space 

Work areas in packaging and labelling lines are often tight. Operators stand between conveyors, machines, and material storage areas, which limits freedom of movement. Workers may reach into narrow spaces, twist to retrieve items, or hold awkward positions while they complete tasks. 

Research from BMC Musculoskeletal Disorders in 2021 reflects how common these issues are: 

• Back pain affects roughly 60% of workers in similar environments 
• Shoulder and neck strain affects 54% 
• Wrist problems affect around 42% 

These figures demonstrate how wide-ranging musculoskeletal issues can be in environments where physical work is constant. 

 

The Cost of Poor Ergonomics & a Lack of Material Handling Safety 

Ergonomics and material handling safety affects more than just comfort. It influences costs, recruitment, productivity, and team stability. Some of these costs appear on paper, while others develop quietly in ways that do not always appear in a budget line. 

Direct Injury Costs 

Although workplace injury rates have declined in some sectors, the cost per claim has risen. An analysis of more than 2.6 million workers compensation claims showed that workers missed around 80 days per injury during 2020-2024, compared with 73 days previously [The Travelers Companies' Injury Impact Report, 2025]. This increase creates long periods of reduced staffing and higher costs. 

Employee Turnover and Training Burden 

Packaging roles that require continuous manual lifting or repetitive work can feel demanding. Workers sometimes leave these positions for roles that place less pressure on their bodies. Even one departure can create a noticeable impact, especially in smaller operations. 

First year workers experience 36% of workplace injuries and account for 34% of all claim costs [The Travelers Companies' Injury Impact Report, 2025]. They are still adjusting to the work pace, still building physical conditioning and being trained. When a trained worker leaves, a new employee enters this early high-risk period. This creates a cycle of injuries and turnover. 

 

Improving Material Handling Safety – Without Large Investments 

Many improvements do not require extensive budgets. In fact, several of the most effective steps rely on observation, small adjustments, and training to improve material handling safety. 

Assess Current Workflows for Risk Factors 

Walk production and labelling lines and observe workers throughout full shifts. Note tasks involving heavy lifting, repetitive movements, awkward postures, or constrained spaces. In addition, it’s important to review injury records for patterns. Palletising, roll mounting, and carton handling consistently are often the highest-risk tasks.  

Reorganise Work to Reduce Strain 

Small adjustments can change how demanding a task feels. For example, moving materials closer to the point of use reduces unnecessary reaching. Adjusting the height of work surfaces can make lifting or folding tasks more comfortable. Clearing floor space to allow natural movement can reduce twisting. 

Rotating workers between tasks breaks up repetitive strain. Someone who spends the morning loading rolls can switch to a lighter task in the afternoon. This variation gives different muscle groups a chance to recover. 

 

Exploring Packaging Automation Solutions 

Some tasks involve loads or movements that cannot be made safe through adjustments alone. In these cases, packaging automation solutions can be beneficial.  

Identifying Tasks That Need Equipment Support 

Equipment may be essential when a task involves frequent lifting of loads above 25 kg, repeated lifting through a full shift, overhead reaching, or awkward angles. Injury records can often highlight the tasks that need attention, such as palletising or roll handling.

Starting with Highest Impact Applications 

No need to install equipment across the whole facility at once. Many operations begin with the tasks that cause the most strain or result in the most injuries. Once improvements are measured and understood, additional areas can be added gradually. 

Want to optimise packaging with reel material handling? Read learn more in our reel handling optimisation article.

Weighing the Options: Manual Vs. Assisted Handling vs. Full Automation 

Understanding the benefits and limitations of manual lifting compared to packaging automation solutions helps facilities make informed decisions. 

Manual Handling 

Advantages: 

• No initial equipment expense 
• Immediate use without equipment training 
• Useful for occasional tasks 

Disadvantages: 

• High risk of strain and injury 
• Lower productivity from fatigue 
• Greater likelihood of damaged materials 
• Dependent on physical strength and staff availability 
• Higher long-term costs through injuries and turnover 
• Unsafe for loads above 25 kg 

Assisted Handling with a Semi-Automated Solution 

Advantages: 

• Lower injury rates and insurance costs 
• Consistent performance throughout shifts 
• Faster throughput and changeovers 
• One operator can manage tasks previously requiring two people 
• Reduced material damage 
• Supports workforce flexibility and cross training 
• Complies with ergonomic safety guidelines 
• Increased ROI (over time) 

Disadvantages: 

• Requires up-front investment 
• Staff training needed 
• Maintenance required 

Fully Automated Robotic Systems

Advantages: 

• Precision and repeatability with 24/7 output 
• Long-term labour savings once implemented 
• Ideal for high-volume production environments 

Disadvantages: 

• Prohibitive upfront capital investment 
• Requires dedicated floor space and safety zones 
• Lengthy implementation and integration periods 
• Limited flexibility for varying product sizes and workflows 
• Potential costly repairs, reprogramming and maintenance 
• Requires extensive operational and safety training 
• Complete workforce replacement rather than skill enhancement 
• Loss of employee expertise and adaptability 
• Complex programming and infrastructure changes required 

Ultimately, the benefits of assisted handling far outweigh the benefits of manual handling or fully automated solutions. 

Understanding Assisted Lifting Equipment  

Assisted lifting equipment takes the weight of the load while allowing the operator to guide its movement. Vacuum lifters handle boxes, bags, and sheets, while lifting trolleys are suited to rolls, drums, and heavier items. 

A clear example comes from Clarebout, a Belgian frozen food producer. Workers there previously lifted 80 kg rolls of packaging film by hand. This created strain and slowed changeovers. 

After installing TAWI lifting systems, a single operator could lift rolls from pallets, tilt them, and move them into machines. The setup improved packaging safety and helped the facility maintain a consistent workflow. 

Read the full Clarebout case study. 

Calculating Return on Investment 

Although assisted lifting equipment requires an upfront investment, many facilities recover the cost within 12 to 24 months. This return comes from improved throughput, fewer injuries, lower insurance premiums, and reduced turnover. 

 

Myth Busting: Packaging Ergonomics and Productivity 

A few assumptions can hold back ergonomic improvements, even when evidence suggests otherwise. 

Myth: Ergonomics Slows Down the Line 

Reality: Workers with less strain and fatigue maintain consistent speed. Assisted lifting often moves materials more quickly than manual lifting. 

Myth: Operators Prefer Manual Lifting 

Reality: Workers value approaches that protect their health. Initial hesitation often fades once operators experience how much easier these systems feel. 

Myth: Equipment Cannot Fit in a Tight Space 

Reality: Compact systems exist for narrow aisles, overhead mounting, or mobile use. Packaging operations often use these solutions without redesigning layouts. 

Myth: Ergonomics Only Help Large Operations 

Reality: Smaller facilities often feel improvements more strongly because each injury or absence affects a larger portion of the team. 

 

Building a Safer, More Sustainable Packaging Operation 

Ergonomics shapes the long-term performance of packaging facilities. Poor material handling safety conditions contribute to injuries, higher costs, and staff loss. Improved ergonomics help protect workers and support consistent production, quicker changeovers, and stronger retention. 

Health and Safety Managers play a central role in improving these conditions. Identifying high-risk tasks, making small adjustments, and providing regular training create a strong foundation for ergonomic improvement. Introducing assisted lifting, where manual handling presents unacceptable risk, can further strengthen safety and workflow stability. 

Facilities that invest in ergonomics benefit financially and have smoother operations. Lower injury rates reduce direct costs. Better retention protects knowledge and skill. Stronger productivity supports long-term competitiveness. Over time, consistent focus on ergonomics builds a healthier workforce and a more reliable operation. 

If you want help in exploring a lifting solution for your packaging operations, reach out to us. 

Or for more information on packaging material handling solutions, visit the packaging industry solutions page.