In industrial environments, pallet ergonomics and overall ergonomic safety should never be the “I’ll get to it later” item on the checklist. Yet many safety hazards, especially those involving poorly used pallet positioners, often go unnoticed until they lead to preventable injuries or costly OSHA recordables.
At DORN Companies, we’ve encountered this issue firsthand during ergonomic evaluations at billion-dollar facilities. Despite the availability of high-quality ergonomic tools, such as spring-actuated, pneumatic, or hydraulic pallet positioners with rotating tops, misuse or non-use remains widespread. In over 50% of cases, these devices are either used incorrectly or not at all, with pallets stacked on top as a shortcut to raise the load, rather than using the adjustable height features as intended.
Ignoring ergonomic best practices is equivalent to using a ball-peen hammer to open a soup can when an electric can opener sits unused. The results? Musculoskeletal injuries, reduced productivity, and skyrocketing costs. According to the Bureau of Labor Statistics, more than 1 million workers suffer back injuries each year from lifting, with each case potentially costing $40,000–$80,000 annually.
Here's how EHS professionals can proactively resolve pallet positioner challenges to improve ergonomics and reduce injury risks.
Top 12 Pallet Handling Problems and Ergonomic Solutions
1. Excessive Bending and Twisting
Problem: Poorly positioned pallets force workers into awkward postures.
Solution:
- Use adjustable lift tables and turntables to maintain loads at waist height.
- Rotate pallets for easy access—eliminating twisting.
2. Reaching Above Shoulder Height
Problem: High stacking leads to shoulder strain.
Solution:
- Store heavy items between hip and chest height.
- Work with vendors to cap pallet height at 50 inches.
3. Repetitive Strain Injuries (RSIs)
Problem: Constant lifting and twisting cause cumulative trauma.
Solution:
- Rotate tasks and encourage micro-breaks.
- Use powered equipment to reduce manual motion.
4. Heavy Lifting
Problem: Manual lifting of large items stresses the musculoskeletal system.
Solution:
- Train on safe lifting practices.
- Use forklifts and pallet jacks.
- Team lift heavy loads.
5. Inconsistent Pallet Heights
Problem: Workers must constantly adjust their posture.
Solution:
- Employ automated stacking systems.
- Standardize pallet height with adjustable racking.
6. Poor Pallet Clearance
Problem: Tight spaces increase strain and reduce movement safety.
Solution:
- Maintain at least 3 feet of clearance around pallet stations.
- Use mobile or height-adjustable systems to enhance flexibility.
7. Unstable Loads
Problem: Shifting items can force sudden, awkward adjustments.
Solution:
- Properly wrap, strap, or net pallet loads.
- Train teams to recognize and secure unstable loads.
8. Visual Strain
Problem: Poor lighting or unclear labels strain eyes and reduce accuracy.
Solution:
- Improve task lighting.
- Use bold, standardized labels and signage.
9. Hazardous or Sharp Items
Problem: Physical injury risk during handling.
Solution:
- Use PPE such as gloves and reinforced footwear.
- Leverage handling tools like tongs or mechanical grippers.
10. Lack of Training
Problem: Workers don't know how to use ergonomic tools.
Solution:
- Provide in-depth, hands-on training.
- Offer periodic refreshers and feedback channels.
11. Prolonged Standing or Walking
Problem: Leads to fatigue and injury.
Solution:
- Use anti-fatigue mats and ergonomic footwear.
- Allow rotation to seated or low-mobility tasks.
12. Harsh Environmental Conditions
Problem: Temperature extremes and poor air quality reduce productivity.
Solution:
- Provide climate control, hydration, and ventilation options.
Final Thoughts: Train, Equip, Empower
Injury prevention doesn’t start and end with equipment purchase; it continues with worker education and proactive safety management. Proper use of pallet positioners can significantly reduce injury rates, decrease downtime, and improve workforce morale.
EHS and Safety leaders: don’t let powerful ergonomic tools go to waste. Train your workforce, monitor usage, and maintain your equipment. It’s not just good safety practice, it’s good business.
Ready to reduce injuries and boost efficiency? Contact DORN Companies today to schedule ergonomic training or injury prevention support tailored to your team’s needs.
