Cuts and Cold in Meat and Poultry Processing Plants

Reading meat processing safety along the line

In a meat or poultry processing plant, risks are distributed not by department but along the product’s journey down the line. Every station from the receipt of live animals to packaging has its own hazard, and these combine with cold, humidity and line speed. For meat processing safety, the best method is to carry out the risk assessment station by station.

The food industry holds an important place in Bursa and the surrounding provinces; meat and poultry processing plants largely work in shifts and depend on the cold chain. The table below summarises the stations of a typical line and the priority measures.

Butcher knife safety: how are cuts prevented?

The most common injuries in meat processing occur to the hand not holding the knife, the forearm and, during deboning when the knife is pulled towards the body, the abdomen and thigh. Butcher knife safety is based on these rules:

• A sharp knife is a safe knife. A blunt knife needs more force; as force increases, so does the chance of the knife slipping and the load on the wrist. The sharpening and steeling arrangement should be in writing, together with who does it and how often.
• The cutting direction is away from the body. If cutting towards the body is unavoidable, the body is protected with a steel mesh apron.
• A falling knife is not caught. If the knife falls, step back and pick it up from the floor.
• Do not walk with a knife. Between stations, the knife is carried in a sheath; it is not left on the bench with the blade facing out.
• The handle must not slip. A slippery or greasy handle causes the hand to slide onto the blade; knives with non-slip handles and hand guards are chosen.
• Knives are cleaned at a separate point. A knife hidden in washing-up water injures a second person.

Steel mesh gloves and other cut protection

In the food sector, the steel mesh glove is worn on the hand not holding the knife and protects against a slipping blade. In work where the knife comes close to the body, such as deboning and cutting, a steel mesh apron and arm guard are also needed. The EN 1082-1 standard is used for steel mesh gloves against hand knives, and EN ISO 13998 for aprons and similar clothing.

For correct use:

1. The glove must fit the hand; a loose glove leaves a gap at the fingertip, and the knife goes into this gap.
2. The rings are checked for breaks or openings at the start of each shift.
3. For hygiene, a thin liner glove may be worn under the glove; the glove is cleaned after each use.
4. For packaging and light work, a cut-resistant knitted glove may be enough; the choice is made according to the job and the risk assessment. For glove classes, see our article on choosing work gloves.

Cold and humid environments, slippery floors

Cutting and packaging halls are kept chilled for product safety; the floor is also constantly wet. Cold hands lose both dexterity and the sense of touch, which makes knife accidents more likely. When working on a conveyor line in a cold environment, these measures stand out:

• Layered, moisture-proof work clothing, thermal underwear and gloves that are insulated but preserve dexterity.
• Regular breaks and hand warming in a warm area; the facility to wash hands in warm water.
• Cold air flow at work positions on the line should not be directed straight at the employee.
• The floor should slope towards drains and be non-slip; the legislation requires floors to be solid, dry and as non-slip as possible. Boots with non-slip soles are used.

For being trapped in a cold room and freezer stores, see our article on working in cold stores, and for risks from the refrigeration system, our article on ammonia refrigeration systems.

Repetitive motion and line speed

On poultry lines, in tasks such as shackling, evisceration and cutting, the same movement is repeated thousands of times per shift. Musculoskeletal disorders such as tendinitis in the wrist, elbow and shoulder and carpal tunnel syndrome are known consequences of this work.

Measures start with line design:

• Line speed and staffing are planned together; when the line speeds up, the number of people at the station is also reviewed.
• Rotation is done between stations using different muscle groups; rotating between two stations that make the same movement brings no benefit.
• Working height is adjusted to the employee’s height with adjustable platforms; overhead reaching is reduced.
• A sharp knife is decisive here too; a blunt knife puts extra load on the wrist with every cut.
• Early reporting is encouraged; numbness, tingling and night pain are reported to the workplace physician.

Zoonoses and biological risks

People working with animal products may be exposed to disease agents that can pass from animals to humans. In poultry processing, bacteria such as Salmonella and Campylobacter, and in red meat, diseases such as brucellosis and Q fever, are addressed in the risk assessment. Under the heading of diseases transmitted from animals in group D of the list of occupational diseases, brucellosis, Salmonella infections and Q fever are listed; the work listed under this heading includes slaughterhouses, butchery, offal processing, sausage making and meat canning. For risk groups and the assessment method, see our article on biological agents and risk groups.

The basic measures are:

• Cuts and grazes on the hands are covered with waterproof dressings; new cuts are recorded.
• Eating, drinking and smoking only in designated areas, with hand washing beforehand.
• Work clothing and everyday clothing are kept in separate lockers, and work clothing is laundered at the workplace.
• An employee with a feverish illness tells the workplace physician about their job.
• The workplace physician assesses the need for vaccination according to exposure.

Work often missed in the risk assessment

Even in plants where the production line has been well assessed, the following work is often overlooked:

1. Night sanitation shift: Cleaning inside machines, high-pressure water and chemicals are used together; cleaning must not be done without locking out the machines.
2. Subcontracted cleaning teams: A team that does not know the line does the riskiest work; coordination and job-specific training are needed.
3. Knife sharpening machines: Grinding wheels and sharpening devices are also work equipment requiring guards.
4. Refrigerant leaks: Evacuation and response must be written into the emergency plan.
5. Forklifts and pallet trucks in cold areas: Braking distance increases on wet and cold floors.

In its OHS specialist and risk assessment services, Bursa Sistemer assesses meat and poultry processing plants along the line; it plans environmental measurements with authorised laboratories and tests with authorised healthcare providers. For other risks specific to the food sector, see our sector page.

Frequently Asked Questions

On which hand should butchers wear a steel mesh glove?

On the hand not holding the knife, that is, the hand holding the product. In work where the knife comes close to the body, such as deboning, a steel mesh apron and arm guard are also needed.

Which risks stand out in a poultry slaughterhouse?

Poultry slaughterhouse risks include knife cuts, repetitive motion in shackling and evisceration, wet and slippery floors, the cold environment, hot water and steam in the scalding section, and dust and zoonoses at live receiving.

Is there a working time limit in a cold processing hall?

The legislation has no fixed working time limit for cold halls. Duration and break arrangements are determined by the risk assessment; regular breaks in a warm area and suitable clothing are the basic measures.

Does brucellosis count as an occupational disease?

Yes. Brucellosis appears in the occupational infectious diseases group of the list of occupational diseases, under the heading of diseases transmitted from animals; the work listed under this heading includes slaughterhouses and butchery.