Manual handling in the textile industry Dr. Ghada Ahmad Mohamad

Manual handling in the textile industry 

Dr. Ghada Ahmad Mohamad 

Lecturer-Spinning Weaving & Knitting Dept. 

Faculty of Applied Arts 

Helwan University 

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Abstract 

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Manual handling in the textile industry 

Dr. Ghada Ahmad Mohamad 

Lecturer-Spinning Weaving & Knitting Dept. 

Faculty of Applied Arts 

Helwan University 

In textiles, manual handling causes more than a quarter of the workrelated 

injuries reported each year. Around 60% of these involve an injury to 

the back, and some result in permanent disablement. Many injuries arise from 

stresses and strains over a period of time rather than from a single event. 

Manual handling problems often stem from poor workplace or job 

design. Among the most common examples of risky activities are jobs 

involving: heavy or awkward loads; difficulty in gripping; excessive use of 

force; repetition; twisting and other awkward postures. 

Costs to the company can come from: loss of production; poor product 

quality; sickness payments; accident injury claims and higher insurance 

premiums; high staff turnover; and retraining. Possible costs to the individual 

are: pain; possible permanent disability; time off work; and loss of earnings. 

1-Introduction 

People responsible for health and safety in the workplace are often in 

the dark as to the proper way to evaluate handling tasks. Standards have been 

set to “quantify” physiological limits but other aspects remain unclear like the 

exact link between bad posture and injuries. The established standards, 

however, are useful used to evaluate the risks associated with specific work 

stations or tasks. If work requirements fall below the set limits, the risk level is 

fairly low; conversely, the risk of injuries increases as the limits are exceeded. 

2-Manual handling 

Manual handling covers a wide range of activities including lifting, pushing, 

pulling. holding. throwing and carrying. It includes repetitive tasks such as 

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packing, typing, assembling, cleaning and sorting, using hand tools and 

operating machinery and equipment. 

Because most jobs involve some type of manual handling, most workers 

are at risk of manual handling injury. Of course, not all manual handling tasks 

are hazardous. But it is significant that around 25% of all workplace injuries are 

caused by manual handling. 

1-1 Manual Handling Risk factors 

Risk factors (also known as “ergonomic hazards”) are conditions that may 

adversely affect a person’s wellbeing and could influence an individual’s ability 

to safely perform an manual handling task. As with most musculoskeletal 

disorders, chronic low back pain usually results from some combination of risk 

factors acting together over time. It should be noted, though, that there is no 

established dose/response relationship. In other words, it is impossible to say 

how many times, or over what period of time, an activity, posture, force, or 

other risk factor can be performed before resulting in a low back 

musculoskeletal disorder. (1) 

1-2 Personal Risk Factors 

A variety of personal qualities and traits, which the worker may bring to 

a manual materials handling job, have been identified as potential risk factors in 

the development of low back pain. These include a prior history of back injury, 

poor personal fitness levels, second jobs, recreational activities, hobbies, 

smoking, the aging process, gender, obesity, physical stature, and psychosocial 

issues (including family, financial or other personal difficulties, job or 

management dissatisfaction, a lack of job control, and work-related stress 

among other factors). 

1-3 Environmental Risk Factors 

Confined or limited workspaces may be considered a risk factor for low 

back pain. Work in spaces that constrain an individual’s posture should be 

eliminated where possible, especially when it affects headroom or horizontal 

reaches. Reaching over obstacles and into containers at a distance from the 

torso places undue strain on the back. Work areas should be unobstructed and 

allow the handler freedom of choice as to how the object is appraised,





approached, and handled. Foot and legroom should be sufficient to allow the 

handler to bend the legs and knees when getting close to the object. Floors 

should be free of debris or materials that might pose a slip, trip, or fall hazard. 

Many materials handling jobs are performed while standing. 

1-4 Workplace Risk Factors 

The workplace risk factors typically associated with low back pain 

include handling heavy loads, task repetitiveness, extreme postures of the back 

(twisting, bending, stretching, and reaching), static postures, whole body 

vibration, prolonged sitting, direct trauma to the back (striking or being struck 

by an object), slips, trips and falls, and work-related stress. 

People performing heavy work, working near their personal strength and 

endurance limits, are more likely to develop back problems than those who 

need to use only a small fraction of their strength capacity. Therefore, the more 

an object weighs, the greater the chance of musculoskeletal injury. 

2- Ergonomic standards 

Ergonomic standards are applied to varying degrees. Following is a list 

of the standards most widely used by ergonomists. 

-ISO Standard 11228-1(2) 

-MMH (3) 

-National Institute for Occupational Safety and Health (NIOSH) equation (4) 

These standards establish maximum loads for manual handling tasks 

performed under optimal conditions . In other words, the standards determine 

the maximum weight that can be safely lifted by workers. The values need to be 

adjusted according to five main factors affecting workers’ health and safety: 

- lifting duration (work-time / recovery-time) : In the assessment of a work 

station involving manual handling, it is crucial to take into account the period of 

time taken by workers to complete the task. The longer this time is, the higher 

the degree of fatigue (5). Factors such as the frequency and duration of 

recovery-time also affect fatigue levels and can reduce the impact of other 

factors such as the total duration of work and the lifting frequency per minute. 

Periods of recovery-time allow workers to compensate for the fatigue caused by 

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repetitive handling tasks, and make it easier for workers to sustain their 

work load. 

- lifting frequency : The second factor is the frequency of handling tasks, 

measured in number of lifts per minute. This element is factored into the 

evaluation of the consequences of load weight and lifting duration on worker 

fatigue. The load itself is not the only consideration and the number of manual 

handling operations performed within a set period of time should also be taken 

into account (lifting frequency). The combined effects of load weight and lifting 

frequency directly affect worker fatigue (6). In addition, increases in lifting 

frequency diminish the worker’s capacity to assess loads (7). Workers who are 

unable to estimate loads correctly will not apply appropriate muscular effort 

and will tire more easily than if they had evaluated the load correctly (8). 

- properties of load : Third, the specific properties of the load should be taken 

into consideration because they affect the way the charge is handled. The 

weight of the load is one example. Another is the location of the load: picking 

up loads from an elevated area is more likely to cause fatigue (4,6) In addition, 

heavier loads increase the risk of musculoskeletal injuries (9). The grip on the 

load is another important feature of the load. The grip is a function of the shape, 

texture (friction rate) and balance of the load. Workers have to exert greater 

force to handle loads with a poor grip in a safe way. For example, handles make 

boxes much easier to handle (10). 

- working environment : The forth factor relates to the working environment. 

This includes the layout of work areas (height of surface where load is picked 

up and deposited), distances covered with and without load, features of 

circulation areas (stairs, graded surface, elevators, etc.) temperature and 

humidity rate. These variables directly affect the level of difficulty associated 

with manual handling tasks . 

- posture of worker: The fifth and final element is the posture adopted by 

workers to carry out handling operations. The physical strength required to 

perform the task increases along with the distance between the center of gravity 

of the load and that of the worker. Excessive distances also cause intervertebral 

disks to compress, increasing the risk of lower back injuries (11)





3-Some common manual handling hazards and solutions in the textile 

industry (12) 

3-1-Loading boxes onto a pallet 

Many workplaces hand stack boxes onto pallets on the floor. Sometimes 

the boxes are large, heavy and awkward in size. 

Risk factors RISK CONTROLS 

Sustained or repetitive 

• Bending the back forwards and twisting more than 20 degrees 

• Reaching forwards or sideways more than 30cm from the body 

• Lifting or lowering 

• Exerting force while in an awkward posture 

Long duration 

High force 

• Using a finger-grip or an open-handed grip to 

handle a heavy or large load 

• Two or more people need to be assigned to 

handle a heavy or bulky load (Figure 1). 

• Stronger employees are assigned to do the task 

• Exerting high force while in an awkward 

posture 

Risk controls 

Altering the workplace 

• Extending a conveyor or use an extension roller 

surface to reduce carrying distances (Figure 2). 

• Placing the pallet on a stand to raise the working 

height to between mid thigh and shoulder height 

and allow access to all sides of the pallet to reduce 

forward reaching and forward back bending 

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Figure (1): Team handling 

of heavy boxes 

Figure (2): conveyor reduces 

carrying of heavy loads

Using mechanical aids 

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• Using a rotating self height adjusting palletiser to reduce the need to bend and 

reach forward to position boxes or sacks on the pallet. 

3-2-Handling long rolls of fabric 

Rolls of fabric or carpet are often awkward shapes to handle in the 

workplace. Frequently, handling involves team lifting. 



• Bending the back forwards more than 20 degrees 



• Gripping with the fingers held wide apart 


Long duration 

High force 

• Lifting, lowering or carrying heavy loads 



• Stronger employees are assigned to do the 

task 


posture 


Figure (3): Team lifting long rolls 

• Ensuring that workstations are at a suitable height so that employees do not 

have to bend to reach rolls






• Using roller conveyors to connect workstations and move rolls on boards. 

This will eliminate the need to lift rolls and enable employees to push/pull them 

easily between workstations 

• Using an overhead crane to eliminate lifting. 

• Installing hydraulic lifting arms on machines to handle rolls 

• Using a tilting roll trolley or a long handle lever trolley which slides under a 

roll, to move rolls between workstations 

• Using a forklift with drum grabber appropriate for the load . 

• Using a probe lifter to move the roll supporting it through the core. This 

reduces the application of force in an awkward posture and enables the task to 

be performed by one employee. 

3-3-Lifting bumps or biscuits from floor level 

Repetitive lifting of bumps or biscuits from the floor or bale bag to a container 

or conveyor involves manual handling risk. This is sometimes performed in the 

dyehouse or whilst loading wool for blending or scouring. 







Long duration 

High force 

• Applying sudden or unexpected forces 


posture (Figure4). 

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Figure (4): Repetitive lifting of bumps 

from the floor in the dyehouse


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• Opening the bale bag onto a table to reduce forward bending of the back to 

pick up bumps or biscuits 


• Putting the bale bag inside a caged trolley with 

a spring loaded system to keep the load at a 

constant height 

• Having bumps delivered in feed cylinders with 

spring loaded bases (Figure 5). 

Figure (5): The bumps are now delivered in feed cylinders with spring loaded bases. 

This reduces forward bending of the back, lifting and the exertion of force in 

awkward postures 

3-4 -Unloading from containers 

Deep sided stillages, trolleys or tubs are often used to move bobbins, tubes, 

cones or skeins. 




• Reaching forwards more than 30cm from the body 

• Standing with most of the body’s weight on one leg 



• Twisting, turning and grabbing actions with the 

fingers, hands or arms 


• Placing the stillage on a stand to raise and tilt the 

load (Figure 6). 

Figure (6): A stand that raises and tilts the load reduces 

the need to bend and reach






• Positioning a spring lift base in the stillage or tub to deliver the bobbins or 

tubes to the operator at a suitable working height 

• Using a stillage tilter to bring items closer to the operator and reduce forward 

bending, reaching and exertion of force in an awkward posture 

Altering systems of work 

• Introducing appropriately designed job rotation in combination with other risk 

controls to reduce exposure to repetitive wrist and forearm 

postures (Figure 7). 

Figure (7): The spring lift insert (shown outside the bin for 

clarity) raises the tubes up to the operator. This 

reduces the forward bending, reaching and the 

exertion of force in an awkward posture 

3-5 -Handling long rolls of fabric 

Rolls of fabric or carpet are often awkward shapes to handle in the workplace. 

Frequently, handling involves team lifting. 

Risk factors RISK FACTORS RISK CONTROLS 





• Gripping with the fingers held wide apart 


Long duration 

High force 





• Exerting high force while in an awkward posture 

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Figure (8): Team lifting long rolls


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• Ensuring that workstations are at a suitable height so that employees do not 

have to bend to reach rolls 


• Using roller conveyors to connect workstations and move rolls on boards. 

This will eliminate the need to lift rolls and enable employees to push/pull them 

easily between workstations 

• Using an overhead crane to eliminate lifting . 

• Install hydraulic lifting arms on machines to handle rolls 

• Using a tilting roll trolley or a long handle lever trolley which slides under a 

roll, to move rolls between workstations 

• Using a forklift with drum grabber appropriate for the load. 

• Using a probe lifter to move the roll supporting it through the core. This 

reduces the application of force in an awkward posture and enables the task to 

be performed by one employee. 

3-6-Handling heavy rolls of fabric 

Handling heavy rolls of fabric or carpet involves high force, often with 

awkward postures. 


High force 


• Two or more people need to be assigned to handle a 

heavy or large load (Figure 9). 



Figure (9): Team pushing large, heavy rolls of fabric





Changing the objects used in the task 

• Installing a roll barrier onto a pallet to allow the 

forklift to transport rolls on the pallet (Figure 10). 

Figure (10): This pallet has been modified with a roll 


barrier to prevent contact with grease from 

the forklift mast. Previously rolls were 

handled manually to keep them clean. 

• Using automated push off systems to move the rolls 

• Using an overhead crane to move rolls 

• Using a tilting roll trolley or a long handle lever 

trolley which slides under a roll, to move rolls 

between workstations 

• Using a forklift with drum grabber appropriate for 

the load (Figure 11). 

• Using a probe lifter to move the roll supporting it 

through the core . 

Figure (11): This automated push-off system eliminates hazardous manual handling 

3-7-Storing rolls of cloth at lower levels 

Some storage racks require the operator to repeatedly obtain rolls of cloth from 

either floor level or above shoulder height. 

Repetitive or sustained 

• Bending the back more than 20 degrees 

• Working with one or both hands above shoulder height 

• Reaching forward or sideways more than 30cm from the body 


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Long duration 

High force 


• Applying uneven, fast or jerky forces during lifting, 

carrying, pushing or pulling 

• Two or more people need to be assigned to handle a 

heavy or large load 



(Figure 12). 

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Figure (12): Pulling rolls of cloth above shoulder height involves high force while in an 

Changing the objects 

awkward posture 

• Reducing the forces required to store and retrieve the rolls by storing materials 

inside larger tubes (Figure 13). 

• Storing rolls in containers that can be moved from 

under racking and lifted with mechanical aids to an 

appropriate height for storing and retrieving. 

Figure (13): By storing rolls inside larger tubes, the forces 

required to store and retrieve the rolls is 

reduced as they are not stored directly on top of each other 

Changing the systems of work 

• Using a fixed height moveable platform with braking system to allow better 

access to the rolls. 

3- 8-Inspecting 

Inspection tasks involve long periods of time looking down at fabric and 

sometimes involve throwing pieces of material onto a table.





Repetitive or sustained 

• Bending the back forwards or sideways more than 20 degrees 

• Bending the neck forwards more than 20 degrees 


• Working with one or both hands above shoulder height 

Long duration 

High force 

• Applying fast or jerky forces during lifting 

• Throwing or catching (Figure 14). 

Figure (14): Sustained forward bending and reaching is a 

manual handling risk 


• Providing options for sitting or standing or adjustable sit/stand seating to 

reduce forward reaching and forward bending of the neck and back. Antifatigue 

matting or foot rests for prolonged standing work can improve 

working postures (Figure 15,16). 

Figure (15): An angled work surface 

reduces forward bending of the back and neck 

Providing mechanical aids 

• Providing an adjustable angle table like a drafting board, to support items 

being inspected to reduce bending of the back and neck and reduce work at or 

above shoulder height. Providing a clamp so that the item remains stable 

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Figure (16): A seat provides options 

for both sitting and standing

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when the table is tilted will also reduce the need for throwing the item on the 

table and the application of fast or jerky forces 

Altering the environmental conditions 

• Providing an alternative lighting colour or lamp design to highlight faults in 

the thread or material and to reduce glare from the light source, or investigate 

whether lighting from underneath would make fault detection easier. This will 

assist in reducing sustained forward neck bending 

Altering systems of work 

• Introducing job rotation in combination with other risk controls to provide 

postural variety and reduce exposure to sustained postures, especially forward 

bending of the neck and back 

Conclusion 

When evaluating manual handling tasks, it is important to take into 

consideration a full range of factors. Following the initial assessment, use 

applicable standards to determine potential hazards. Recommendations are then 

issued to reduce the risk factors. The impact of recommendations can 

be determined by using the set standards. If the assessment reveals that 

standards are being respected, apply the recommendations. Prevented can assist 

with the evaluation of handling tasks, for instance by sending a specialist to 

analyze the situation and suggest appropriate solutions. Recommendations aim 

to lower the constraints noted and can help develop tailored solutions. Workers 

and production managers are consulted prior to 

the implementation of any suggestions. They may also wish to develop their 

own set of corrective measures; these should be validated by a specialist in 

ergonomics to ensure they are appropriate. 

References: 

1- Stephen B. Randall," A Guide to Manual Materials Handling and Back Safety" ,N.C. 

Department of Labor Bureau of Education, Training and Technical Assistance,1997. 

2- International Standard Organization (ISO), May 2003. Ergonomics – Manual handling. Part 

1: Lifting and carrying. ISO 11228-1.





3-Mital, A., Nicholson, A.S., and Ayoub, M.M. A guide to manual materials handling (MMH). 

Second Edition. Taylor & Francis. 1997. 

4-Water, T.R., Putz-Anderson, V., Garg, A., and Fine, L.J. Revised NIOSH equation for the 

design and evaluation of manual lifting tasks. Ergonomics, 1993, 36 (7), 749-776. 

5-Asfour, S.S., and Tritar, M. Endurance time and physiological responses to prolonged arm 

lifting. Ergonomics, 1991, 34 (3), 335-342. 

6-Genaidy, A.M., and Asfour, S.S. Effects of frequency and load of lift on endurance time. 

Ergonomics, 1989, 32 (1), 51-57. 

7-Karwowski, W., Shumate, C., Yates, J.W., and Pongpatana, N. Discriminability of load 

heaviness : implication for psychophysical approach to manual lifting. Ergonomics,1992, 35 (7- 

8), 729-744. 

8-Patenaude S., Marchand D., and Bélanger M. Influence of load incertainty on physiological 

demand. Short communication International Society of Electrophysiology and Kinesiology - 

ISEK XII, 1998. 92-93. 

9- Hidalgo, J., Genaidy, A., Karwowski, W.,Christensen, D., Huston, R., and Stambourgh, J. A 

comprehensive lifting model : beyond the NIOSH lifting equation. Ergonomics, 1997, 40 (9), 

916-927. 

10- Stälhammar, H.R., Louhevaara, V., and Troup, J.D.G. Rating acceptable loads in manual 

sorting of postural parcels. Ergonomics, 1996, 39 (10), 1214-1220. 

11- Chaffin, D.B., and Andersson, B.J. Occupational biomechanics, 3rd ed. John Wiley & Sons, 

inc. New York. 1999. 579 pp. 

12- Victorian workcover Authority. Manual handling solutions in the textile industry. 

Melbourne Victoria. October .2002 

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Manual handling in the textile industry Dr. Ghada Ahmad Mohamad

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