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Adding to the many serious safety and health hazards for poultry workers — such as noise levels, dangerous equipment, and hazardous chemicals — are material handling hazards. From walking-working surfaces, to stacking and storing materials, poultry workers are constantly faced with safety challenges.
The Bureau of Labor Statistics (BLS) estimates that occupational injury and illness cases for the poultry industry are six times the average for all U.S. industries. Musculoskeletal disorders are of particular concern for poultry workers mostly due to repeated lifting, bending, and twisting motions as well as standing for prolonged periods of time.
The poultry industry would come to a stand-still if not for warehousing and material handling operations. Supplies and processed poultry are typically either transported to trucks for immediate shipment or are placed in a warehouse for storage. Material handling and warehousing involves:
The most common material handling hazards encountered during poultry processing operations include:
Poultry workers and material handlers are often required to stack boxes overhead, which forces them to bend their torso forward to place the box on a pallet or the top of a stack. Even when conveyors are used to transport materials directly to refrigerated trucks, workers are required to lift the material from the conveyor, then stack them in trucks above head height or at floor level. This can result in back and shoulder injuries.
Shelving, racks, and other stored materials (pallets, cages, etc.) can injure workers if not inspected and maintained in a way that prevents collapse, sliding, or tipping over. Loose materials should always be stacked or packaged to prevent tipping or extending into aisleways. Forklifts can also be a cause of material collapse if upright or corner guards aren’t used to prevent damage to shelving and racking systems.
One of the most common causes of injury in poultry processing facilities are slips, trips, or falls. This is due to a continuous influx of debris from processing and rinsing of floor surfaces for sanitation reasons. It’s vital that floors and aisles be kept clear of spills, clutter, electrical cords and water hoses, and other hazards that could cause result in a slip, trip, or fall. Slippery or wet floors that don’t have adequate drainage and stairs without handrails or slip-resistant surfaces can also result in catastrophic falls. Additionally, poultry processing areas are often cold, resulting in ice formation that could result in injuries or strain from slipping, especially if the worker was carrying a load when they slipped. Workers are also susceptible to falls from unprotected edges or sides of docks or platforms greater than 4 feet in height, so must be protected.
Poultry industry workers may be exposed to a litany of ergonomic hazards, musculoskeletal stressors, and excessive noise. Lifting, twisting, bending, reaching overhead, pushing and pulling heavy loads, and working in awkward body postures can take a toll on workers, especially when these tasks are performed repeatedly. These repetitive movements increase workers’ risks of musculoskeletal disorders (MSDs), including back and shoulder pain, muscle strains, carpal tunnel syndrome, and tendinitis. Excessive noise from machinery, animals, forklifts, and alarms can also put employees at risk of hearing loss if not managed properly. Ergonomic stressors and excessive noise, coupled with the fast past of production, can also result in stress and fatigue for workers, which is yet another risk for injuries or illness that must be managed.
Where chemicals are present in poultry processing areas or warehouses, employers are subject to OSHA’s Hazard Communication standard (HCS) (29 CFR 1910.1200). Maintaining a written HazCom program and chemical inventory, keeping chemicals labeled and safety data sheets (SDSs) accessible, and training workers will go a long way toward hazardous chemical compliance.
Working in cold environments may keep the poultry cold, but it can create hazards for workers. Working in the cold requires them to wear extra clothing, which can restrict movement and increase their exerting force when lifting and moving materials. These movements can result in serious back strains and other injuries. Also, individuals that work in cold environments will burn more energy to maintain body heat and therefore are susceptible to fatigue or injury more quickly.
Employers must perform hazard assessments and implement appropriate controls to mitigate risks and prevent employee injuries. This includes guarding machinery, enforcing safety procedures, and offering effective training.