So, it’s no small wonder that print firms, with technological improvements at their disposal (if at a price) are eager to engineer as much manual handling out of the process as humanly (or should that be in-humanly?) possible.

Of course, there’s huge benefits to taking as much strenuous activity out of the printing process. At York-based Ryedale Group, steps are taken to minimise the amount of manual handling involved in the production process, but as James Buffoni, managing director, explains, sometimes it’s unavoidable – or indeed, undesirable. 

“I can’t say that it’s impossible to remove manual handling,” he says. “Our sales orders are typically complex, and our works orders can be made up of a range of sales orders so we have developed custom robotics for many years, which help to reduce manual handling in key areas for quality and throughput purposes, but there has to be a cost benefit. 

“In some of our processes, such as palletisation of smaller boxes which can take place in a number of areas, manual handling can be more flexible and help us to create efficiencies. The solutions need to stack up from a number of angles: well-being, cost benefit, flexibility and so forth.”

Split loads, level workflow, use of pallet trucks and forklifts are just a few of the methods which the company employs to reduce the amount of physical human interaction with the product. Ryedale is also reviewing the benefits of further automation as part of process development, investigating the use of pallet and product transit systems, gravity conveyors that could further reduce the amount of manual handling involved in the process. And for when it’s absolutely necessary, the proper training is given, including physical demonstration of the correct process.

The benefits are clear: “We see reduced absence from work from manual handling related conditions, primarily back aches and strains,” says Buffoni. 

Failing training 

But while many printers are investing in the equipment and infrastructure to eliminate manual handling, one of the most important factors that needs to be considered is actually making sure the training that’s provided to staff is relevant. The HSE last year issued a warning to businesses that ‘off-the-shelf’ handling training doesn’t pay dividends and is, in fact, a waste of everyone’s time. Explaining at the launch of new advice by the body in March, HSE’s Health and Work portfolio manager Geoff Cox said: “Our research shows that simplistic training involving bending your knees to lift a cardboard box is just a waste of time and money, it just doesn’t make any difference.” 

Some of the biggest risks involved for printers, according to HSE’s principal inspector, Giles Hyder, include transportation and loading of reels and sheets, pile turning, loading and unloading guillotines, knocking up of sheets of paper and paper stacking. “Relevant solutions include pile-turners and joggers to reduce hand turning or knocking up, swing arm hoists and slings at reel-stands, reel conveyor trolleys, scissor lifts and elevating tables at folders and guillotines, free running or mechanical conveyors, cylinder and roller trolleys and reel shaft trolley,” says Hyder.

“It’s impossible to eliminate all manual handling from printing activities, although there are different approaches to ensure staff carry out their duties in a safe and controlled manner. There are many mechanical aids available that support the avoidance of many of the more strenuous tasks,” adds Mandy Robson, head of health, safety and environment at BPIF.

Among the various systems that are helping printers cut down on the amount of manual handling that takes place in the plant is the Heidelberg Polar Flowline, a comprehensive guillotine system that includes the Polar 115N cutter, a stacklift, jogger and Transomat. It has already found favour with printers including Bristol’s Philtone Litho and Lancahsire-based Printplus Group. Philtone’s Neil Mercer explained the move, citing putting less strain on factory operatives as a major reason for the installation. “Cutting will become less strenuous and that is the thinking behind this investment. Operators get tired when they are always lifting. The system will be good for operators and also alleviate bottlenecks and increase throughput which is good for the business and for our customers,” he said, on announcement of the kit’s arrival. The company claims that productivity is up a third since it has come into play.

Of course, kit costs money, but it can be a worthwhile investment reckons Robson – and sometimes, it’s just a matter of changing procedure. 

“Yes, any mechanical aids will have a cost associated with introduction, but to put this into context, any suffering of employees due to a lack of mechanical aids leads to approximately 8.9 million working days lost per year within the industry due to work-related musculoskeletal disorders. Therefore, the way we see it, the investment is a worthwhile benefit to avoid any loss of manpower within the business. 

“Saying this, not all manual handling risks are prevented by purchasing mechanical aids, some can simply be either avoided or carried out in a safe manner by changing the working procedure therefore the initial assessment of risk, management of controls and improvements to the work activities is essential.” 

Sometimes, getting around manual handling requires a bit of creative thinking. “There are many innovative ways where businesses employ an in-house maintenance team or who have links to an impressive handy-man,” says Robson. “I’ve personally seen trolleys adapted to manage 55kg wire reels from pallets on to machines and mechanically lifted into position. Also, there are various paper reel adaptions that support the movement and positioning of reels. I always encourage member companies to think outside the box, involve operatives and to work together to identify the ideal solution.”

Roll with it

For Iain Clasper-Cotte, managing director at Leeds-based flag and fabrics printer Northern Flags, eliminating much of its manual handling was an objective when it moved into its new site in December last year. It was an essential move, after the company started using utilising much bigger kit and taking larger orders, with minimum widths of 3.2m. “When you’re dealing with rolls of fabric and PVC, they’re heavy so it’s really important,” says Clasper-Cotte. The company has invested in specialist lifting equipment. “We were already using it but bought more,” says Clasper-Cotte. “We encourage people to use it – it’s much safer than having two people carrying rolls around the place.”

With a new factory to move into, steps were taken to make the production process as least reliant on manual handling as possible – a move which makes the workplace more efficient as well as safer. “A lot of the time its s about workflow – if you plan a factory efficiently you have to carry things less,” says Clasper-Cotte. “When the next stage in the process is close, it speeds things up, as well as minimising strains on your staff.”

When it comes to making sure that staff are up to speed when they do have to get lifting or moving, an external consultant is used. “We get 100% buy-in from staff; a lot of it might seem a bit obvious, but for us it’s important to remind people of the basics, because they can get into bad habits.”

For Gary White, managing director at Belfast-based digital print outfit Northside Graphics, eradicating manual handling is a desirable thing to have in the production process, but not always the best for the product. “Basically, it’s the holy grail,” he says. “It’s very difficult to achieve, but it’s about finding points it works for.”

“There’s a skill to printing – cutting down business cards can be done easily, but other things need a level of human intervention,” he says. “Because we’re an upload-to-print service, if we fully automated the process entirely and someone supplies inferior artwork, then they won’t be happy with the final product. We try to automate the pre-press, but only if the artwork is correct. When it comes to finishing there are elements that are automated but we tend to remain more manual because of quality control,” he says. “It all starts with artwork – if it’s perfect or pre-existing you can automate all the way through.”

A key part of the company’s automation is software-based, but it isn’t an instant fix and takes time to perfect. “When you buy software out of the box, it’ll take about 3,000 hours to get the systems to work properly.”

White advises taking a look at some of the processes on the factory floor and working from there when it comes to introducing automation to replace manual handling. “If it’s manual and you’re doing it again and again then automate it,” he says.

“I think some printers will achieve that holy grail (of full automation) but I’m yet to be convinced that people aren’t the most important element – I suppose it could work if we were a factory making widgets but we’re making uniquely personalised projects,” he says. “I think ultimately a lot of the automation has come about because its so difficult to entice people into the industry,” he says. “Print needs highly skilled people – and we don’t want to lose them.”

But eliminating as much manual handling in printing, and importantly, getting the training right when it’s a necessity could be a very important factor in retaining skilled people, as Robson explains. “One of the most under-estimated benefits is the promotion of a safer, healthier and happier workforce with a greater understanding of the roles and jobs they are to fulfil,” she says. “It has been widely cited that a healthy workforce has benefits on productivity. Manual handling training promotes this by teaching good, efficient and safe practice within the workplace.”