Editor's Note: This article was originally published on 10/12/2024. It was updated on 22/07/2026.   

Food Packaging Process Continuously Changes  

The process of packaging food products has undergone a vast transformation over the years.  Some of the most beautiful items in our museums– clay or earthen jars and vessels – represent our ancient efforts to create suitable packaging. 

Currently, a popular trend is making food packaging more sustainable. Companies are turning to biodegradable or recycled materials, so packaging is better for the environment. An example is using paper-based materials instead of plastics. But sustainable packaging needs different lifting considerations because it can be fragile. 

With each technological wave, packaging has evolved. But the food packaging process also needs to stay adaptable to change. 

Can the Food Manufacturing Process Keep Up?  

Yes, but it won’t happen by accident. Food manufacturing facilities need to establish flexible processes that can handle when packaging changes. 

First, it’s important to remember what the purpose of packaging is. 

• Protect contents from outside elements 
• Reduce contamination 
• Increase life span of contents 

In the food and beverage industry, the wide range of weights and sizes necessitates diverse packaging solutions.

The diversity in packaging means there are different types of items workers will have to handle. Common items workers have to lift at a food facility are: 

• Bags/sacks 
• Boxes 
• Drums 
• Reels/rolls 

But no matter the food packaging type, it always need to be carefully handled, lifted, and moved. It’s crucial that no damage comes to the packaging or contents. Otherwise, companies might face inventory loss from contamination or spoilage. 

Food and ingredients are not the only things that need protecting. Your workers' health and safety also need to be considered. It’s important to strike the right balance between efficient operations for maximum profitability and prioritising worker health and safety. 

The Painful Reality of Manual Lifting 

One way companies stay flexible and handle different types of food packaging is manual lifting. Workers can move their arms to accommodate the size of different items. If products become heavier, more workers could work together to lift one item.  

However, manual lifting has serious safety challenges and can lead to injuries. 

For example, musculoskeletal disorders (MSDs) like upper limb disorders, back injuries, and chronic ailments are a risk. These issues often arise from repetitive tasks and awkward lifting, leading to chronic back pain. 

1.  Risk to People 

In the United States during 2023-2024, the #2 cause of occupational injuries that caused an employee to miss work were overexertion, repetitive motion, and bodily condition. This was about 27% out of all injuries, according to NSC Injury Facts. 

There are direct costs of employee injuries and indirect costs. The indirect costs can cover things such as retraining or replacing an injured employee, scheduling and production delays, administrative expenses, legal costs, hiring difficulty, and even lower employee morale. 

2. Risk to Products 

Manual handling also risks the integrity and safety of food products. There is a chance for human error where the workers falls or drops the item. 

It’s also hard for a human to lift every item the exact same way. So, there is inconsistency in the process. 

The good news? Most of these risks are preventable.

It all begins with creating a sustainable, ergonomic workplace. Companies should prioritise safety to reduce worker absences and keep operations running smoothly. 

Increasing food packaging process efficiency 

Smart companies are taking a closer look at worker safety and working conditions, and how they affect company costs and profits. Many are turning to ergonomic solutions to mitigate risks for their employees.  

Any responsible packaging manager is familiar with ergonomics and wants to design/arrange workplaces, products and systems that fit human abilities and limitations. 

So, one solution to consider is lifting solutions that can increase the capabilities of each and every worker, and create a safer, more efficient, and more profitable workplace. 

Food Packaging (Re)evolution in Action: Enhance Efficiency and Safety 

Many workplace injuries are linked to worker fatigue. Working in the packaging industry can be physically taxing, and the longer a worker performs their tasks, the more tired they become.  

Tired workers are more likely to make mistakes which can put them and fellow employees at risk and increase the likelihood of injury. Lifting solutions never get tired – or injured – they just keep working.  

Semi-automated vacuum lifters and trolley solutions enable any worker to lift, safely and efficiently, without damage to the products or the people who handle them.  

• Bags are bulky, unwieldy, and the center of gravity can shift. Lifting solutions can firmly lift bags to keep the product and operator safe. 
• Reels are heavy, ungainly, and hard to lift quickly. Lifting trolley can make lifting reels easy and reduce downtime. 
• Boxes can be heavy and cause physical strain from repetitively lifting them. Vacuum lifters can create quick and safe box lifting in one spot or around a facility. 
• Drums can be large, hard to grab, and heavy. Drum lifting can overcome awkward lifting for faster, smoother processes. 

Protect Your Products: How to Minimise Damage and Prevent Contamination 

Another challenging situation is the packing or palletising of the ingredients or raw materials used in food and beverage products. Any tears or holes in the bags or sacks could allow foreign substances to contaminate the materials, potentially rendering them useless or dangerous to consume.  

TAWI’s line of vacuum lifting equipment removes this danger when lifting food. They quickly and carefully move, stack, or handle even the most fragile of food or packaging with no risk of damage to either products or employees. 

Improved Ergonomics = Economics 

The way you manage your handling and lifting procedures can dramatically impact your bottom line. The math is simple: 

Negatives keep building 

Inefficient lifting operations -> wasted or injured labour -> unneeded cost 

But positives can keep building also 

Increased handling safety -> increased efficiency -> improved employee and customer retention 

The smart lifting advantage  

At TAWI, we use our extensive knowledge and expertise to tailor products and solutions to match your specific situations and your unique needs – call it ergonomics in action.  

We help companies evolve towards a more profitable process with: 

• A more flexible workforce 
• A safe and healthy workplace 
• Reduced absence due to injury 
• Minimised damage and loss 

Also, we offer a wide variety of suction feet and attachments, so one piece of equipment can lift different types of items. This flexibility means the equipment can adapt if your lifting needs to change. 

Take Action over Your Lifting with the Right Partner 

Whether for reels, bags, boxes, canisters, cartons, pallets, or barrels, or even the direct handling of food products, TAWI stainless steel lifts and trolleys ensure safe and ergonomic lifting at all stages of your packaging process.  

TAWI lifting equipment is low cost, low maintenance, easy to install, requires minimum effort to use, and is easy to clean and disinfect – a crucial requirement in many food packaging environments. 

With TAWI solution lifting solutions for the food packaging industry, you can optimise operations, reduce damage and waste, and make employees’ jobs easier and safer. 

Contact us to discuss how you can make your food packaging process more efficient with a TAWI solution.