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Packout - Whole Bird Bulk Packaging

Task 2: Unloader/Box Filler



unloader/box fillerBirds are lifted directly from a conveyor and are placed into a shipping box. Employees may lift up to 3 birds in each hand. They may also need to reach up to about shoulder height to access birds and bend over at the waist to place birds in the packing box.

Hazards of the task may include:


Bending at the waist to place birds into packing boxes
Hazardous Situation:
Repeatedly bending forward and reaching out away from the body stresses the back even if there is little weight being lifted because the upper body must be supported. When loads are being lifted, bending over at the waist increases the distance the load is held away from the body and increases the stress placed on the back.
Possible Solutions:
  • Use a diverter to push birds off the conveyor directly into the box so employees do not need to manually lift product.
  • Provide a height-adjustable packing stand so boxes can be loaded without bending at the waist.
  • Use a tub dumper at the workstation to empty contents on the conveyor.
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Forceful gripping of slick product
Hazardous Situation:
Employees lift multiple birds at one time, usually by the legs. Lifting 2-3 birds in each hand is not uncommon. Birds are cold and slick; employees usually wear rubber gloves that are also slick and may not fit well. All these factors increase the finger force that must be exerted. Exerting significant finger force can stretch and fray the tendons of the hand and can create a contact trauma to the tendon and sheath where they come in contact with bone or tendon. These types of actions increase the risk of tendonitis and carpal tunnel syndrome.
Possible Solutions:
  • Use a diverter to push birds off the conveyor directly into the box so employees do not need to manually lift product.
  • Provide a height-adjustable packing stand so boxes can be loaded without bending at the waist.
  • Use a tub dumper at the workstation to empty contents on the conveyor.
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Reaching to elevated work areas
Hazardous Situation:
Employees may be working at a position where they must reach up to access birds for packing. Tasks that force the employee to reach up and/or out are stressful to the shoulders and upper back.
Possible Solutions:
  • Use a diverter to push birds off the conveyor directly into the box so employees do not need to manually lift product.
  • Provide a height-adjustable packing stand so boxes can be loaded without bending at the waist.
  • Provide a height-adjustable work platform so employees can adjust their height in relation to the conveyor.
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