Manual handling injuries are the most common injury type in Australian food processing, accounting for the majority of workers compensation claims in the sector. Workers lift, carry, push, and position heavy ingredient bags, product containers, trays, and packaging materials throughout every shift. Repetitive tasks such as packing, stacking, and palletising create cumulative musculoskeletal damage even when individual loads are below standard weight limits. Wet and cold environments increase injury risk by reducing grip strength and foot traction. This template maps controls to the binding Hazardous Manual Tasks Code of Practice effective 1 July 2026 under Section 26A.
WHS Regulation 2025 Part 4.2 — Hazardous Manual Tasks
Hazardous manual tasks
Hazardous Manual Tasks (binding 1 July 2026 under Section 26A)
Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.
| Hazard | Consequence | Likelihood |
|---|---|---|
| Lifting heavy ingredient bags and product containers | Back injuries, disc prolapse, shoulder injuries | Almost Certain |
| Repetitive packing, stacking, and palletising movements | Cumulative musculoskeletal disorders, tendinitis | Likely |
| Pushing and pulling heavy trolleys on wet floors | Back strains, slip injuries during exertion | Likely |
| Awkward postures during low-level packing and shelf stacking | Knee injuries, back strain | Likely |
| Reduced grip from cold, wet, or greasy conditions | Dropped loads causing foot injuries | Possible |
| Sustained standing on hard floors during packing operations | Lower limb fatigue, varicose veins | Likely |
Worker suffered severe injuries in food processing facility where safety procedures were inadequate.
2023 — SafeWork NSW v B&E Foods Pty Ltd [2023]
Worker injured in food processing facility due to inadequate equipment safety controls.
2023 — SafeWork NSW v Inghams Enterprises Pty Ltd [2023]
Our ergonomics consultants build task-specific SWMS that reduce musculoskeletal injuries and meet WHS Regulation 2025 requirements for your food processing operations.
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