How To Reduce Repetitive Strain Injuries When Palletising

Reducing repetitive strain injury (RSI) when palletising products involves a combination of ergonomic practices, proper techniques, and equipment adjustments. This downloadable calculator will help you to analyse your current process and the risk of RSI occurring.

Here are some tips to help minimise the risk of RSI:

  1. Proper Training:
    • Ensure that workers receive adequate training on proper palletising techniques. This ensures that workers are aware of proper techniques for lifting, carrying, and palletising.
    • Teach them the importance of maintaining good posture and body mechanics. Knowing how to use their bodies efficiently reduces unnecessary strain on muscles and joints.
  2. Use Ergonomic Equipment:
    • Invest in palletising aids that are designed with ergonomics in mind, such as manual palletising aids and lift tables. Palletising aids and lift tables can help workers maintain comfortable and neutral body positions and is designed to reduce physical strain and promote more natural movements.
    • Implement conveyor systems to reduce the need for manual lifting and carrying.
    • Invest in automated systems, such as robotic palletisers, that remove the need for manual handling and therefore remove the risk of RSI occurring. I
    • If container unloading is involved, invest in a lifting boom with an integrated man cage to remove the need for people to use a step stool, or climb on top of boxes in the container, to reach the top boxes.
  3. Workstation Design:
    • Design workstations with ergonomic principles, ensuring that the height of the pallets and work surfaces is appropriate for the workers. Proper height and layout reduces the risk of reaching or bending excessively and prevents awkward postures, therefore reducing the strain on the body.
    • Provide anti-fatigue mats to reduce the strain on the feet and legs during prolonged periods of standing.
  4. Regular Breaks:
    • Encourage workers to take regular breaks to stretch and change positions, reducing the strain on specific muscle groups. Regular movement during breaks helps improve blood circulation and reduces muscle stiffness allowing workers to rest and recover and preventing cumulative fatigue that can lead to RSI.
  5. Job Rotation:
    • Implement job rotation to vary the tasks workers perform. Job rotation ensures that workers are not consistently performing the same repetitive tasks, distributing the workload more evenly across muscle groups.
  6. Reduce Repetition:
    • Optimise the workflow to minimise unnecessary movements and repetitions; reducing the strain on specific body parts.
    • Use mechanical assistance such as pallet jacks or forklifts to move heavy loads as this reduces the need for manual lifting and repetitive motions.
  7. Proper Lifting Techniques:
    • Train workers in proper lifting techniques, including bending at the knees, keeping the load close to the body, and avoiding twisting motions. This minimise the risk of muscle strain and injury during manual handling tasks.
  8. Stretching Exercises:
    • Incorporate stretching exercises into the daily routine to improve flexibility and reduce muscle stiffness. Stretching exercises improve flexibility and reduce muscle stiffness, enhancing overall mobility and reducing the risk of strain.
  9. Personal Protective Equipment (PPE):
    • Provide workers with proper PPE, including gloves and back support belts, to help protect against strain and injuries. These provides additional physical support and protection, reducing the strain on specific body areas.
  10. Workplace Assessments:
    • Regularly assess the workplace to identify and address any potential ergonomic issues that may contribute to RSI, ensure that the workspace is optimised for worker health and safety.
    • Solicit feedback from workers to understand their concerns and make necessary adjustments.
  11. Health and Wellness Programs:
    • Implement health and wellness programs that promote overall physical well-being, including exercise and stress reduction. Programs promoting overall health and well-being contribute to better physical fitness, which can reduce the risk of RSI.
  12. Consult with Occupational Health Professionals:
    • Seek guidance from occupational health professionals to assess the workplace and provide recommendations for reducing the risk of RSI. Occupational health professionals can provide expert guidance in identifying and addressing potential RSI risks in the workplace.

By implementing these solutions collectively, employers can create a more ergonomic and worker-friendly environment, thereby reducing the risk of repetitive strain injuries among employees. Regular monitoring, feedback, and adjustments help maintain a proactive approach to workplace safety and employee well-being.


Bag PalletiserBag Palletiser
Barrel PalletiserBarrel Palletiser
Box PalletiserBox Palletiser
Crate PalletiserCrate Palletiser
Tray PalletiserTray Palletiser

This entry was posted in Auto Palletiser, Automated Container Unloading, Automated Palletising, Bag Palletiser, Box Palletiser, Cobot Palletiser, Container Destuffing, Container Destuffing Palletising, Container Unloading Palletising, Granta Updates, Palletiser - Granta GA15 Palletiser System, Palletising, Robotic Palletising and tagged , . Bookmark the permalink.