Packaging line workers’ safety is tied to their well-being and manufacturers’ bottom lines. Protecting them from on-the-job injuries goes hand in hand with a facility’s success. To maintain productivity levels and revenue, you must minimize workplace hazards.

Safety concerns on the packaging line

It’s the facility manager’s responsibility to ensure the safety of workers on the packaging line. You can only do that if you know the workplace hazards specific to their roles.

Workers on the packaging line face multiple hazards:

• Equipment failure: If machinery fails during operation, workers on the packaging line could be struck, cut, entangled or shocked. 
• Vibration: Hand-arm vibration can damage small blood vessels and nerves over time.
• Repetitive motion injuries: Repeatedly lifting, bending, grabbing or rotating without frequent breaks can strain muscles, leading to fatigue and overexertion. 
• Noise: Consistent or sudden loud noises can irreparably damage workers’ hearing.
• Slips and falls: Faulty machinery and defective packaging can leak, making workers prone to slip-and-fall accidents.
• Exposure to hazards: Pharmaceutical, consumer goods and chemical manufacturing facilities could expose workers to physical and airborne hazards on the packaging line.

Understanding what workers are up against can help you plan safety procedures and prepare for emergencies. Be mindful that your facility’s equipment may introduce additional hazards — a facility-specific approach is always best. 

How workplace injuries impact manufacturers

On-the-job injuries don’t just affect manufacturing workers — they also impact manufacturers’ bottom lines. They can lead to medical expenses and legal fees. Even with insurance, you might end up paying a hefty sum out of pocket because of administrative costs, overtime pay or missed deadlines. 

Unplanned downtime is one of the main drivers of financial losses. In 2020, private manufacturers reported 373,300 nonfatal injuries and illnesses, 36.4% of which required days away from work. This sudden labor shortage can impact your facility’s productivity, affecting your ability to meet demand or fulfill contracts.

In many cases, on-the-job injuries cause prolonged — or permanent — productivity losses. According to the National Safety Council, they accounted for around 70 million of the 103 million lost workdays in 2021. The other 33 million were from permanently disabling injuries. On average, that adds up to a loss of 150 days per worker. 

Late deliveries can impact your relationship with clients, potentially causing future financial losses if they decide not to renew their contracts. Your priority should be improving worker safety to protect your facility’s bottom line and keep clients happy. Preventing on-the-job injuries from occurring avoids lost workdays and related expenses.

Improving facility safety can avoid those losses. A safe manufacturing process ensures operations are efficient while protecting workers from harm. While it doesn’t guarantee you’ll see revenue or productivity increases, there’s a high likelihood that workers will be more driven if they aren’t as afraid of on-the-job injuries. 

How to keep workers on the packaging line safe

You can take multiple steps to keep workers on the packaging line safe from everyday hazards. 

Use proper product packaging

The right barrier packaging can reduce exposure hazards. Reputable providers ensure ingredients won’t migrate into or out of the package, which prevents workers from coming into contact with hazardous chemicals or pharmaceuticals. Minimizing leaks can also reduce equipment contamination and slip-and-fall accidents. 

Hand out PPE for ergonomics

Ergonomic personal protective equipment (PPE) is lightweight, comfortable and flexible. It’s ideal for workers who regularly strain themselves with awkward postures or repetitive motions. Examples include a back brace, knee protection, padded work boots and adjustable earmuffs. They can also help protect against noise, vibration and falls.

Train workers on safety

Training can help you reduce on-the-job injuries. Research shows workers’ knowledge of occupational health and safety increases from 73% to 94% after a few training sessions. Help them help you by giving them the tools to maintain a safe packaging line on their own.  

Keep workstations clear

You should ensure workers keep their surroundings as clear and organized as possible. A clean workstation is one of the main contributors to a safe workplace because it reduces the chance of slip-and-fall accidents and exposure to physical hazards. It also helps establish a safety-first culture, encouraging everyone to follow procedures.

Give workers more breaks

Giving workers on the packaging line a five-minute break every hour or so can help reduce their risk of noise, vibration or motion-related damage. While the slight dip in productivity may seem unacceptable, you shouldn’t think of it as cutting into your bottom line. The time and money you’ll save from reducing on-the-job injuries more than makes up for any perceived loss. 

Workplace safety is an ongoing commitment 

Once you develop a plan and establish procedures, your job is to ensure workers remain compliant. You can do this by stressing the importance of safety, encouraging them to follow the new policies and reminding them of their commitment. 

If your facility is like most, one day of training won’t be enough. Research shows workers forget 50% of the material within a few days. Periodically conducting safety sessions ensures they remember what they learned and helps them understand the importance of doing so.

Encouraging workers to follow your established policies is as easy as rewarding compliant behavior. For example, you could create a point system and give prizes to those who pass certain thresholds. Alternatively, you could praise them in front of their colleagues.

Even if your workers follow procedures precisely as they’re supposed to, you should still consider reminding them of their responsibility. Displaying helpful signs about what ergonomic PPE to wear or how to avoid certain injuries can help them remain mindful of safety.

The bottom line of packaging line worker safety

The manufacturing industry is inherently dangerous to some level — heavy machinery, moving parts, loud equipment and messy work create the perfect environment for hazards. Even though you won’t be able to prevent every on-the-job injury, you can still protect most workers by developing the proper procedures and establishing a safety-first culture.