Reducing Repetitive Taping and Strapping Risks at the Packing Bench

A packing bench can look like one of the safer areas in a warehouse. There may be no heavy machinery, elevated work or fast-moving vehicles immediately nearby. However, repetitive taping, strapping and carton handling can still place considerable strain on workers over the course of a shift.

The latest Australian work health and safety data shows why these everyday tasks deserve attention. Body stressing accounted for 50,600 serious workers’ compensation claims in 2023–24, representing 34.5% of all serious claims. Manufacturing and transport, postal and warehousing were also among the six industries accounting for most serious claims nationally.

Safe Work Australia identifies repetitive movement, repetitive or sustained force, high or sudden force and awkward postures as characteristics that can make a manual task hazardous. Its manual tasks guidance specifically uses packing goods from a conveyor into cartons as an example of repetitive work.

Look beyond the weight of each item

A roll of tape or handheld dispenser may not be particularly heavy. The risk can come from how frequently it is used and the position of the worker’s hands, wrists, shoulders and back.

Common issues at packing stations can include:

• Repeatedly pulling tape against resistance
• Holding the wrist at an awkward angle while sealing cartons
• Reaching across wide boxes
• Twisting between the bench, conveyor and finished pallet
• Lifting cartons from below knee height
• Bending to pass strapping beneath a pallet
• Carrying heavy strapping coils
• Manually tensioning straps throughout the shift

These movements may appear minor when observed once. Repeated hundreds of times, however, they can create sustained exposure to the same physical demands.

Start by observing the actual packing process

Improvement should begin with watching the complete task rather than focusing only on how an individual worker holds a tape dispenser.

Look at where cartons arrive, where tape and strapping are stored, how far workers need to reach and where completed packages are placed. Ask operators which parts of the job require the most force or become uncomfortable later in the shift.

A consumable placed slightly out of reach can result in hundreds of unnecessary reaches each day. A pallet positioned too low can require repeated bending. A poorly organised bench can also cause workers to handle the same carton multiple times before it is ready for dispatch.

Consulting the people who perform the task can reveal issues that may not be obvious during a brief inspection.

Bring frequently used materials within easy reach

Tape, labels, cutters, seals and other frequently used items should be positioned where they can be reached without excessive bending, twisting or stretching.

The working height should also suit the size of the cartons and the task being performed. WorkSafe Victoria has previously recommended trialling equipment heights with workers and using mechanical aids to keep materials at more practical working levels. Its guidance also notes that banding can involve awkward reaching and force when packs are tightened manually.

There is rarely one ideal bench arrangement for every carton. Businesses handling a wide variety of products may need adjustable surfaces, roller sections, pallet-positioning equipment or separate areas for unusually large packages.

Reduce the force required

A worn dispenser, unsuitable cutter or poorly maintained strapping tool can make a repetitive task more demanding than it needs to be.

Tools should suit the consumable, load and frequency of use. They should also be inspected and maintained in accordance with their manufacturer’s instructions.

Possible improvements may include:

• Using dispensers that unwind smoothly
• Keeping cutting components sharp and properly guarded
• Using coil dispensers rather than carrying loose strapping
• Selecting lighter tools where appropriate
• Suspending heavier equipment to reduce lifting
• Using battery-powered strapping tools where they are suitable for the application

WorkSafe Victoria’s manual handling guidance identifies powered ratchets, suspended tools and automatic strapping as possible ways to reduce the force and awkward postures associated with manual steel strapping.

Consider the whole workflow before introducing automation

Automation should not be treated solely as a way to package more products per hour. In the right application, equipment may also reduce repeated pulling, cutting, bending and manual tensioning.

A tape dispenser that provides a preset length can remove repeated measuring and cutting. A semi-automatic strapping machine may reduce the amount of manual tensioning required. A case sealer may provide more consistent tape placement while changing the operator’s role from repeatedly applying tape to positioning and checking cartons.

The correct solution depends on package dimensions, volume, consumable type, workflow and the remaining tasks performed by the operator. Introducing equipment without considering loading, unloading and access can simply transfer the physical demand to another part of the process.

Small changes can make a meaningful difference

A packing process does not necessarily need a complete redesign to become easier to perform.

Moving consumables closer, raising a pallet, reducing double handling or replacing an unsuitable tool may all improve the task. Where exposure remains high, more substantial engineering controls or partial automation may be justified.

Cyklop Australia supplies packaging consumables, dispensers, strapping tools and packaging equipment for different operating volumes and applications. Reviewing the consumable, tool and workstation together can help create a packing process that is both reliable and more practical for the people performing it.

This article provides general information only. Workplace risks and controls should be assessed for the specific task, equipment and operating environment.