Severe injuries from product movement in the U.S. food supply chain

The modern food supply chain presents unique hazards to employees that result in higher morbidity and mortality rates versus other industries. Employees in food manufacturing, wholesaling, and even retailing experience relatively high numbers of occupational injuries and fatalities. One reason for the high hazard rates may be the reliance on a synergistic packaging system designed to load and transport food products within and between manufacturers, wholesalers, and retailers. Packaged food products are often aggregated using palletizers before they can be transported by forklifts and pallet jacks. Materials handling within facilities is critical to the efficient functioning of all members of the food-related supply chain, but product movement can be a source of occupational injuries. No previous research has examined the cause and result of such hazards.

This paper aims to examine severe injuries related to the packaging and movement of food products in segments of the food and beverage supply chain from manufacturing to retailing. An OSHA database was used to investigate all severe injuries in the six years from 2015 to 2020. The focus was on the food supply chain for the period since OSHA began mandating new reporting procedures for severe injuries.

Results show there were 1,084 severe injuries and 47 fatalities during the six-year period. Fractures of the lower extremities were most prevalent, with the most frequent event type being transportation-related such as pedestrian-vehicle incidents. Significant differences were seen in the three parts of the food supply chain.

Implications are drawn for key sectors of the food-related supply chain to reduce packaging- and product movement-related hazards.