Managing 25kg Ingredient Sacks: Using the HSE MAC Tool to Find Practical Solutions
Many bakeries handle 25kg bags of flour, sugar, mixes and other ingredients every day. Rather than focusing on technique alone, the HSE Manual Handling Assessment Charts (MAC) tool looks at the factors that make handling more demanding and helps identify where improvements are needed. The assessment considers load weight, handling frequency, carrying distance, reach, lifting height, grip, workplace layout and environmental conditions.
The aim is simple: identify the factors driving risk and improve them.
Example 1: Flour delivered on pallets beside the mixer
Task
25kg flour sacks
Lifted 20 times per shift
Picked up from waist-height pallet
Carried 2 metres
No twisting
Good grip on sacks
Clean, level floor
Under the MAC assessment, the weight and frequency would attract attention, but most other factors remain favourable. The task may be manageable without major investment if good standards are maintained.
Potential improvements
Position pallets as close as possible to the mixing point.
Rotate stock so sacks are always removed from the top layers first.
Avoid storing bags directly on the floor.
Reduce carrying distances wherever possible.
A pallet positioner can keep loads closer to waist height and reduce bending as pallets empty. Reducing the distance between the load and the body significantly lowers stress on the lower back.
Typical cost. £300 to £1,500
Example 2: 25kg sacks taken from storage room to production
Task
25kg sacks
Frequent handling
Carried 12 metres
Through doorways
Around corners
Occasional floor contamination from flour dust
This task scores more highly because carrying distance, obstacles and floor conditions all contribute additional risk. The MAC tool recognises that distances over 10 metres and routes containing obstacles increase manual handling demands.
Potential improvements
Move ingredient storage closer to point of use.
Deliver pallets directly into production.
Introduce wheeled handling equipment.
Improve housekeeping and floor cleaning.
Mechanical aids are specifically identified by HSE as a preferred way to reduce manual handling risk
Typical costs:
Sack Truck £80 - £250
Platform Trolley - £120 - £500
Hand Pallet Truck - £250 - £800
Electric Pallet Truck - £1500 - £4000
Trigger Points for Considering Mechanical Assistance
The following findings during a MAC assessment should prompt consideration of handling aids:
Repeated handling
A 25kg sack lifted repeatedly throughout the shift quickly moves into higher-risk MAC scoring bands. More frequent lifting increases the need for controls.
Floor-level lifting
Regular lifting from floor level scores significantly higher than lifting between knee and elbow height.
Reaching forward
If employees cannot stand close to the sack because of pallets, shelves or equipment, risk increases substantially.
Carrying more than 10 metres
The MAC tool treats carries above 10 metres as a higher-risk factor.
Twisting or restricted space
Handling in narrow areas, around obstructions or while twisting should trigger a review of workplace layout or equipment options.
Employee complaints
The MAC guidance recommends prioritising tasks that workers describe as difficult, tiring or uncomfortable.
Equipment Worth Considering
| Equipment | Best for | Typical Cost |
|---|---|---|
| Pallet positioner | Reducing bending | £300–£1,500 |
| Sack truck | Occasional movement | £80–£250 |
| Platform trolley | Frequent transport | £120–£500 |
| Hand pallet truck | Palletised ingredients | £250–£800 |
| Electric pallet truck | High throughput sites | £1,500–£4,000 |
| Vacuum sack lifter | Heavy repetitive handling | £5,000–£20,000 |
| Mobile lifting hoist | Loading and unloading | £1,000–£5,000 |
Examples of lifting aids recognised in HSE guidance include sack trucks, hoists, pallet trucks, conveyors and vacuum lifting systems.
Practical Takeaway
When assessing 25kg ingredient sacks, do not ask whether employees have been trained to lift correctly. Ask what score the task would receive under the MAC tool and which risk factors are driving that score. If sacks are handled frequently, carried long distances, lifted from floor level, or moved in restricted spaces, improvements to storage, layout or handling equipment are likely to provide greater risk reduction than additional lifting training alone
Contact Information
Contact: Emma Milne Chartered Environmental Health Officer
E-mail: emma@saferfoodscores.co.uk
Tel: 01442 877322