TOP 5 MANUAL HANDLING CHALLENGES IN THE FROZEN-FOOD SUPPLY CHAIN

In the frozen-food industry, the demand for efficiency, hygiene and safety is ever-increasing.

According to the Health & Safety Executive (HSE), over 30% of reported acute injuries in the food & drink sector stem from manual handling tasks such as lifting, lowering, carrying or moving loads.  In a frozen-food environment – where cold temperatures, slippery surfaces, stacked pallets, and time pressures are the norm – these risks are amplified.

As a specialist in forklift attachments tailored for cold and hygiene-critical environments, Contact Attachments Ltd shares the top five manual-handling challenges facing frozen food operations, along with practical hints and equipment-based solutions that can help mitigate them.

 

1. Heavy loads and awkward stacking/unstacking

One of the most common causes of injury in food & drink manufacturing is handling heavy boxes, crates, sacks or palletised loads – especially when stacking or de-stacking.  In a frozen-food warehouse, loads are often bulky, may be stacked high, and must be moved quickly to maintain the cold-chain.

Why it’s a challenge:

• Loads above shoulder height or from the floor demand awkward lifting, increasing musculoskeletal strain
• In freezers or chillers, workers may lift heavier loads while wearing bulky gloves or protective gear, reducing dexterity and increasing physical demand
• Time pressures can encourage workers to lift manually rather than utilise specialist lifting equipment.

What to do:

• Risk-assess all tasks involving heavy/awkward loads – can the load be reduced, split, or moved mechanically?
• Use purpose-built attachments for example fork extensions) to avoid manual lifting of heavy or unstable loads.
• Ensure stacking heights are within safe reach, and loads are secured to reduce manual handling after stacking.

 

2. Working in the Cold – Extra Strain and Slip Hazards

Frozen and chilled storage introduces additional manual-handling hazards.  Working in sub-zero temperatures slows down response times and increases fatigue – and added to that, surfaces may be icy or wet.

Why it’s a challenge:

• Reduced grip when wearing cold-weather PPE (gloves, heavy boots etc)
• Slips, trips and falls become more likely on icy or wet flooring – the HSE estimates that slips/trips in wet/icy areas cost UK business £millions annually

What to do:

• Provide and enforce suitable non-slip footwear, gloves and PPE designed for freezer use
• Minimise manual handling in freezer zones: use attachments designed for cold environments (for example, stainless-steel, corrosion-resistant) so that forklift attachments rather than people bear more of the load
• Implement ergonomic designs – avoid manual lifting of goods from the floor in a freezer, ensure good lighting and flooring condition, and schedule regular breaks for workers exposed to cold.

 

3. Repetitive tasks, high volumes and operator fatigue

High-throughput frozen-food operations often involve repetitive manual tasks – unpacking, loading, stacking, transferring goods, and repeated handling of products.

Why it’s a challenge:

• Repetition of the same manual lifting, pushing or pulling actions contributes to fatigue
• Pressure to fulfil tight schedules (e.g. peaks during seasonal demand) can reduce time for safe manual handling
• Manual pick-and-pack work in cold rooms is especially

What to do:

• Rotate tasks to avoid prolonged exposure to the same manual handling activity
• Introduce mechanical aids – forklift attachments that reduce manual lifting (e.g. drum rotators or bulk-handling shovel attachments)
• Ensure workers are trained in manual-handling technique (especially for the cold-storage environment) and recognise signs of fatigue or strain

 

4. Poor load stability and awkward load types

In frozen food operations, not all loads are uniform or easy to handle – pallets may be double-stacked, cages may be heavy or awkward, loads may be unstable due to ice or condensation.

Why it’s a challenge:

• Irregular or unstable loads require more manual intervention to adjust, reposition or stabilise
• Manual movement of roll cages or pallets on slippery floors (especially in freezers) adds strain.

What to do:

• Choose forklift attachments that improve load handling efficiency (e.g. pallet pullers which reduce the need to manually reposition pallets)
• Ensure load design is appropriate, load heights are safe, and worker access is ergonomic (e.g. not requiring stretching or twisting).
• Conduct risk assessments for all manual handling of irregular/unstable loads

 

5. Inadequate training, assessment and equipment-mismatch

Even with the best equipment and policies, the root of many manual-handling issues lies in insufficient risk assessment, poorly matched equipment, and inadequate worker training.  The HSE emphasises that many manual-handling injuries are preventable through mechanisation and training.

Why it’s a challenge:

• Frozen-food operations often operate 24/7, with multiple shifts and high staff turnover – so ensuring consistent manual training can be more difficult.
• Equipment (forklifts, attachments, racks) may be standard ambient-temperature models, not suited to freezer conditions which can increase manual handling load
• Risk assessments may not account for the unique cold-storage hazards – heavier gloves, slower reflexes, icy surfaces, bulk loads, stacking at height – all of which increase manual handling risk.

What to do:

• Conduct regular, task-specific manual handling risk assessments, including in cold/chiller/freezer zones. The ‘avoid–assess–reduce’ approach of the Manual Handling Operations Regulations (MHOR) remains a key framework.
• Provide role-specific training, updated for cold-store conditions (in heavier gloves, with floor/temperature hazards in mind)
• Invest in attachments and handling equipment designed for the environment, rather than relying on general-purpose equipment
• Ensure inspection and maintenance of attachments and forklift equipment in cold-conditions so that mechanical aids remain reliable and reduce the need for manual intervention.

 

The frozen-food supply chain presents unique manual handling challenges – heavy and/or unstable loads, repetitive tasks, cold environments, and equipment mismatches.  But by taking a systematic approach – assessing risk, upgrading equipment, training staff and utilising specialist attachments – both manual handling demands and the risk of injury can be significantly reduced.

With over 50 years’ experience in designing forklift attachments for the food & drink industry, Contact Attachments supports frozen-food operations with bespoke solutions that are hygiene-safe, cold-store compatible and ergonomically smart.  They’re proud to work alongside BFFF members in helping make the chain of frozen-food logistics safer, cleaner and more efficient.

If you’d like to discuss how the right attachment can reduce manual handling in your chilled or frozen operations – or to conduct a review of your site – please contact the team on 01686 611200 or via their website at www.forklift-attachments.co.uk.