ERGONOMIC SOLUTIONS

FOR RETAILERS

Prevention of Material Handling 

Injuries in the Grocery Sector

DEPARTMENT OF HEALTH AND HUMAN SERVICES

Centers for Disease Control and Prevention

National Institute for Occupational Safety and Health
ii • ERGONOMIC SOLUTIONS for Retailers

TRAINING REQUIREMENTS

As with any mechanical device before using, employees need to be trained and in some 

cases certified to use devices that are self-propelled. OSHA and NIOSH supplies safety 

information in working with pallets, pallet jacks, conveyors, as well as other mechanical 

devices. See the following:

https://www.osha.gov/SLTC/etools/woodworking/commonhaz_forklifts.html

https://www.osha.gov/SLTC/poweredindustrialtrucks/standards.html

https://www.osha.gov/dte/library/pit/ppt/index.html

http://www.cdc.gov/niosh/docs/2001-109/

The main hazard associated with using or working around mechanical assists and 

pallets are injuries identified as “contact-based” which are common in warehouses and 

back storage areas where space is often limited. Further information on the hazards in 

the retail and wholesale sector are discussed in Anderson et al. [2010].

This document is in the public domain and may be freely copied or reprinted.

DISCLAIMER

Mention of any company or product does not constitute endorsement by the National Institute for Occupational Safety and Health (NIOSH). In addition, citations to websites external to 

NIOSH do not constitute NIOSH endorsement of the sponsoring organizations or their programs 

or products. Furthermore, NIOSH is not responsible for the content of these websites. All web 

addresses referenced in this document were accessible as of the publication date.

SUGGESTED CITATION

NIOSH [2014]. Ergonomic solutions for retailers: prevention of material handling injuries in the 

grocery sector. By Anderson VP. Cincinnati, OH: U.S. Department of Health and Human Services, 

Centers for Disease Control and Prevention, National Institute for Occupational Safety and 

Health, DHHS (NIOSH) Publication No. 2015-100.

DHHS (NIOSH) Publication No. 2015-100

October 2014

Safer • Healthier • PeopleTM
ERGONOMIC SOLUTIONS for Retailers • iii 

PREVENTION OF MANUAL MATERIALS HANDLING INJURIES

Disclaimer and Training Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Ergonomic solutions for grocery retailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Manual material handling jobs in the retail grocery industry . . . . . . . . . . . . . . . . . . 2

Unloading pallets from a trailer with a powered-pallet jack . . . . . . . . . . . . . . . . . . . 3

Place products on conveyor for transport to store . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Remove boxes from conveyor to handcart for sales floor . . . . . . . . . . . . . . . . . . . . . . 5

Remove boxes from conveyor onto U-Boat for sales floor . . . . . . . . . . . . . . . . . . . . . 6

Unload pallet onto handcart for transport to sales floor . . . . . . . . . . . . . . . . . . . . . . 7

Moving excess merchandise from a flat cart to storage rack . . . . . . . . . . . . . . . . . . . 8

Using a pallet stacker to move a loaded pallet to storage rack . . . . . . . . . . . . . . . . . 9

Using a pallet stacker to move excess merchandise to storage rack . . . . . . . . . . . . 10

Using a vacuum lift to load or unload bags of material from a pallet . . . . . . . . . . . 11

Using a pallet jack to move boxes from back room to sales floor . . . . . . . . . . . . . . 12

Using a stocking cart to place products on shelves . . . . . . . . . . . . . . . . . . . . . . . 13,14

Using stocking cart with a tilted container to stock small products . . . . . . . . . . . . . 15

Sources for preventing manual material handling injuries . . . . . . . . . . . . . . . . . . . . 16

Sources for information from business/labor trade associations . . . . . . . . . . . . . . 17

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TABLE OF CONTENTS
iv • ERGONOMIC SOLUTIONS for Retailers

REDUCE INJURIES — USE ERGONOMIC SOLUTIONS

Author

Vern Putz Anderson

Acknowledgments

This booklet was inspired by the “Ergonomic 

Guidelines for Manual Material Handling.”

Appreciation is extended to 

the following:

 Eugene Smith for his unique and 

realistic illustrative style and to Al Tudor 

for his content and design input;

 NIOSH production staff of Vanessa 

Williams and Gino Fazio for their 

expertise in graphic design and 

production, and Christy Forrester for 

her editorial assistance;

 Members of the NORA Wholesale and 

Retail Trade (WRT) Sector Council who 

helped shape the nature and content 

of this booklet (http://www.cdc.gov/

niosh/nora/); and,

 The Ergonomic Assist Systems and 

Equipment (EASE) Council and chair 

for the review of the ergonomic assist 

equipment and its usage.

ACKNOWLEDGMENTS

Figure: An employee loading a box on to an 

elevated pallet. This figure is a preview of an 

illustration shown in greater detail on Page 10, 

Figure 8.
ERGONOMIC SOLUTIONS for Retailers • 1 

Figure: An employee operating a 

pneumatic lift and moving device. 

More details on Page 11, Figure 9.

Purpose

This booklet was designed for retailers 

and safety experts to illustrate the use of 

mechanical assist devices for reducing 

manual materials handling (MMH) injuries in 

retail grocery work.

This booklet provides illustrations of 

employees in a retail grocery store using 

mechanical assist devices to perform material handling tasks. For each task, there 

are multiple devices that can be used. 

The types and numbers of such devices 

that are used in a retail business depend 

on the nature of the business and the 

type of work employees perform. The 

technology presented will also support 

a retailer’s growing internet sales that 

depends on moving large quantities of 

merchandise in a short time span and 

often with fewer employees.

Additional information on this topic can 

be found at the end of this document 

in two sections entitled: “Sources for 

Preventing Manual Material Handling 

Injuries” and “Sources for Information 

from Business/Labor Trade Associations”. 

The drawings are not intended to depict 

the mechanical details of each assist 

device, but rather are intended to provide 

an illustration that shows how and where 

an employee would use such a device.

ERGONOMIC SOLUTIONS

FOR GROCERY RETAILERS

REDUCE INJURIES — USE ERGONOMIC SOLUTIONS
2 • ERGONOMIC SOLUTIONS for Retailers

The series of four illustrations below represent material handling job 

activities involved in the movement of materials from the delivery truck to 

the sales floor. The following pages will describe mechanical assist devices 

that can be used during each activity to reduce stressful postures and 

handling of heavy loads.

MANUAL MATERIAL HANDLING JOBS 

IN THE RETAIL GROCERY INDUSTRY

REDUCE INJURIES — USE ERGONOMIC SOLUTIONS

Unload truck and transport 

merchandise to the store 

using a conveyor

Transport and unload 

merchandise onto 

storage racks

Transport and unload 

merchandise from the truck 

onto the sales floor

Transport and unload 

merchandise from storage 

onto the sales floor

1

3

2

4
ERGONOMIC SOLUTIONS for Retailers • 3 

UNLOADING PALLETS FROM A TRAILER

 WITH A POWERED-PALLET MOVER

Figure 1 shows an employee unloading a trailer stocked with pallets 

of merchandise using a powered-pallet mover with a riding platform.

Although, the device reduces the risk of material handling injuries, it does 

pose an added risk of a contact-with-object injury, such as bumping into 

the side of the trailer. Training is required to enable the operator with a 

loaded pallet to move safely across the loading dock’s threshold into the 

facility’s receiving area.

REDUCE BENDING AND REACHING MOTIONS
4 • ERGONOMIC SOLUTIONS for Retailers

PLACE PRODUCTS ON CONVEYOR 

FOR TRANSPORT TO STORE

Figure 2 shows an example of a height-adjustable conveyor. With 

this type of conveyor, one person can do what two or more individuals 

normally do in unloading a trailer. Height adjustable conveyors can 

also reduce extreme bending and allow the boxes to be placed on the 

conveyors rather than dropped which could damage the container and/or 

contents. A sturdy step stool or platform is needed to reach the top levels 

of the interior of the trailer, which range from 7.5 feet (2.3 m) to 9.0 feet 

(2.7 m) high.

REDUCE BENDING AND REACHING MOTIONS
ERGONOMIC SOLUTIONS for Retailers • 5 

REMOVE BOXES FROM CONVEYOR 

TO HANDCART FOR SALES FLOOR

Figure 3 shows an employee who is removing boxes from a conveyor 

to load on a two-wheeled, self-adjusting handcart. Handcarts of this 

type are used frequently in moving beverages and containers of similar 

weights. In addition to saving time, adjustable handcarts reduce bending 

by keeping the load at or near waist level. Most adjustable handcarts 

operate with a spring or counterbalancing system.

REDUCE BENDING MOTIONS
6 • ERGONOMIC SOLUTIONS for Retailers

REDUCE BENDING AND EXCESSIVE REACH

REMOVE BOXES FROM CONVEYOR ONTO 

U-BOAT FOR SALES FLOOR

Figure 4 shows an employee in two positions as she unloads boxes from 

a conveyor onto a U-Boat platform truck in which a spring-loaded platform 

has been added. In the first position she is grasping the box. In the second 

position she turns her feet and body to face the platform truck. The U-Boat 

outfitted with spring loaded platform is designed to reduce bending by 

keeping the load at or near waist height either when loading or unloading 

containers. The narrow platform deck reduces excessive reaching.
ERGONOMIC SOLUTIONS for Retailers • 7 

UNLOAD PALLET ONTO HANDCART FOR 

TRANSPORT TO SALES FLOOR

Figure 5 shows an employee unloading boxes from a pallet onto a 

powered adjustable handcart. The pallet is resting on a rotating and 

adjustable base that may be adjusted mechanically or pneumatically to 

set the height at waist level. The turntable minimizes reaching across or 

walking around the pallet.

REDUCE BENDING AND EXCESSIVE REACH
8 • ERGONOMIC SOLUTIONS for Retailers

MOVING EXCESS MERCHANDISE FROM 

A FLAT CART TO STORAGE RACK

Figure 6 shows an employee unloading onto the storage shelves from 

a flat cart, outfitted with a spring-loaded platform. The intent of this 

device is to reduce excessive bending in loading and unloading materials 

located at or near the bottom of the flat cart. Best practices suggest 

stocking lighter weight goods on the lower level shelves. Knee pads are 

also an option if kneeling is required to stock lower shelves.

REDUCE BENDING AND LIFTING FORCES
ERGONOMIC SOLUTIONS for Retailers • 9 

USING A PALLET STACKER TO MOVE 

A LOADED PALLET TO STORAGE RACK

Figure 7 shows an employee with a battery powered pallet stacker 

picking up a full pallet. The full pallet is resting on a height-adjustable, 

pallet-loader table. The task here is either to move the full pallet to the 

sales floor or to move the pallet to a storage area away from a busy work 

area. The pallet stacker is designed to place a full pallet on a shelf for 

easy retrieval at a later time.

REDUCE LIFTING AND CARRYING FORCES
10 • ERGONOMIC SOLUTIONS for Retailers

USING A PALLET STACKER TO MOVE 

EXCESS MERCHANDISE TO STORAGE RACK

Figure 8 also shows an employee using a pallet stacker to position 

the pallet next to, and even with, the shelf-edge allowing the box to be 

pushed onto the shelf without bending and lifting motions. Best practices 

suggest stocking lighter weight goods on the lower level shelves. Knee 

pads are also an option if kneeling is required to stock lower shelves.

REDUCE LIFTING AND CARRYING FORCES
ERGONOMIC SOLUTIONS for Retailers • 11 

USING A VACUUM LIFT TO LOAD OR UNLOAD 

BAGS OF MATERIAL FROM A PALLET

Figure 9 shows an employee operating an overhead vacuum or air hoist 

to move large bags of materials to flat carts or pallets (not shown). A 

vacuum lift device can alleviate the repetitive stress of lifting and moving 

of unstable materials. A main advantage is the lifting task can be done 

in less time by nearly any employee regardless of size and strength, thus 

increasing productivity.

REDUCE LIFTING AND LOWERING FORCES
12 • ERGONOMIC SOLUTIONS for Retailers

USING A PALLET JACK TO MOVE BOXES 

FROM BACK ROOM TO SALES FLOOR

Figure 10 shows an employee pushing a manual pallet jack through 

the doors separating the stock area from the sales area. Pallets jacks or 

trucks are designed to lift and move a pallet. Although the pallet is able to 

hold large amounts of stock, thus reducing the number of trips between the 

back room and sales floor, pallets can pose a trip hazard to those in the 

immediate area, as well as blocking customers’ access to the products.

CONVERT CARRYING FORCES TO PUSHING
ERGONOMIC SOLUTIONS for Retailers • 13 

USING A STOCKING CART TO

PLACE PRODUCTS ON SHELVES

Figure 11 shows an employee with the aid of a stocking cart placing 

products on the store shelves using both hands, which increases his 

efficiency. This device was also designed to reduce excessive bending, 

holding, and reaching when stocking shelves. The top shelf slides up and 

down to keep the shelf at a better position for stocking shelves, while 

minimizing excessive bending. 

REDUCE BENDING AND AWKWARD POSTURES
14 • ERGONOMIC SOLUTIONS for Retailers

USING A STOCKING CART TO 

PLACE PRODUCTS ON SHELVES

Figure 12 shows an employee also using a stocking cart. The man is 

stocking the top shelf and is able to keep the extra stock on the shelf of 

the stocking cart, which has been raised to its top position. Two hands 

are being used for stocking, as there is no need to hold the carton in one 

hand and stock with the other.

REDUCE BENDING AND AWKWARD POSTURES
ERGONOMIC SOLUTIONS for Retailers • 15 

USING STOCKING CART WITH A TILTED 

CONTAINER TO STOCK SMALL PRODUCTS

Figure 13 shows an employee stocking small goods from a tote 

(container) held in position by the stocking cart. By tilting the tote, awkward 

postures involving the shoulders, arms, and wrist are reduced, which 

lessens muscle fatigue and improves productivity. This type of stocking cart 

is particularly useful in stores where small items are stocked and sold, such 

as in the health and beauty aids departments in grocery stores.

REDUCE BENDING AND HOLDING CONTAINER
16 • ERGONOMIC SOLUTIONS for Retailers

SOURCES FOR PREVENTING MANUAL 

MATERIAL HANDLING INJURIES

Ergonomic Intervention for the Soft 

Drink Beverage Delivery Industry

http://www.cdc.gov/niosh/pdfs/96-109.pdf

NIOSH conducted a study to investigate, identify, 

and reduce risk factors that may cause musculoskeletal disorders and injuries in the soft drink 

beverage delivery industry. The engineering/ergonomic controls, in combinations with improved 

work practices, reduced worker fatigue, reduced 

multiple handling of beverage cases, and decreased awkward postures. 

National Occupational Research Agenda 

for Musculoskeletal Disorders

http://www.cdc.gov/niosh/docs/2001-117/

pdfs/2001-117.pdf

Work-related musculoskeletal disorders (MSD), 

such as low back pain, tendinitis, hand-arm 

vibration syndrome and carpal tunnel syndrome, 

account for a major component of the cost ($13 

to $54 billion annually) of work-related illness 

in the U.S. The “Intervention Research Agenda” is 

found on pp. 10–11, and 22–23.

Ergonomic Guidelines for Manual 

Material Handling

http://www.cdc.gov/niosh/docs/2007-131/

pdfs/2007-131.pdf

Manual material handling tasks may expose 

workers to physical risk factors. If these tasks 

are performed repeatedly or over long periods 

of time, they can lead to fatigue and injury. The 

main risk factors, or conditions, associated with 

the development of injuries in manual material 

handling tasks are described on pp. 9–14.

Guidelines for Retail Grocery Stores: 

Ergonomics for the Prevention of 

Musculoskeletal Disorders 

https://www.osha.gov/Publications/osha3192.pdf

This document provides practical recommendations to help grocery store employers and 

employees reduce the number and severity of injuries in their workplaces. The document focuses 

on effective approaches for assessing the need 

for ergonomic solutions. Ergonomic solutions that 

deal with stocking activities are found on p. 19.

Elements Ergonomics Programs: A 

Primer based on Workplace Evaluations 

of Musculoskeletal Disorders

http://www.cdc.gov/niosh/docs/97-117/

pdfs/97-117.pdf

This primer provides basic information that will 

be useful for employers, workers, and others 

in designing effective programs to prevent 

work-related musculoskeletal disorders. NIOSH 

introduced the seven step pathway for evaluating 

and addressing musculoskeletal concerns in an 

individual workplace. See section on warehousing material handling and supermarket checkout 

operations on pp. 7–8, 21.

Grocery Warehouse Ergonomics: 

OSHA ETool

https://www.osha.gov/SLTC/etools/

grocerywarehousing/packaging.html#pallets

This eTool describes example ergonomic hazards 

and solutions in grocery warehousing with an 

emphasis on traditional order picking, which 

accounts for a large number of musculoskeletal disorders. However, many of the examples 

are also applicable to the other types of Order 

Picking. Information is provided on hazards 

associated with pallets and the importance of 

maintenance of devices.
ERGONOMIC SOLUTIONS for Retailers • 17 

Ergonomic Assist Systems and 

Equipment (EASE)

http://www.mhi.org/ease

EASE is the resource for information, practices, 

equipment, and organizations that focus on ergonomics and improving the working interface between people and the materials to reduce injury 

and increase productivity. Ergonomic equipment 

promotes the safety and health aspects of work 

environments for people.

The Loss Prevention Foundation (LPF)

http://www.losspreventionfoundation.org

LPF is an international leader in educating and 

certifying retail loss prevention and asset protection 

professionals. LPF’s mission is to advance the retail 

loss prevention and asset protection profession 

by providing relevant, convenient and challenging 

educational resources. The LPF is exclusively created to serve the education needs of the retail loss 

prevention and asset protection professions.

National Grocers Association*

http://www.nationalgrocers.org

This is the national trade association representing 

the retail and wholesale grocers that comprise the 

independent sector of the food distribution industry. 

NGA provides the latest education and research 

to help independent retailers increase profits and 

grow their operations. Serving their industry through 

sharing information, education, and research.

Food Marketing Institute (FMI)

http://www.fmi.org

FMI is an organization that conducts food 

safety, public affairs, education, research, and 

industry relations programs for food retailers 

and wholesalers. FMI’s membership consists of 

approximately 1,500 companies in 50 countries, 

ranging from large multi-chain stores to independent supermarkets.

Retail Industry Leaders Association (RILA)

http://www.rila.org

RILA promotes consumer choice and economic 

freedom through public policy and industry operational excellence. RILA provides a forum where 

members can conduct discussions aimed at understanding common operational practices, areas of 

concern, and pragmatic solutions to problems.

Material Handling Industry (MHI)

http://www.mhi.org

MHI is the nation’s largest material handling, 

logistics and supply chain association. MHI offers 

education, networking and solution sourcing for 

members and their customers through programming and events. MHI is concerned with the movement, protection, storage and control of materials.

The United Food & Commercial Workers 

(UFCW) International Union

http://www.ufcw.org/

UFCW is are made up of more than 1.3 million 

people working primarily in grocery and retail 

stores, and in the food processing and meat 

packing industries. UFCW members work to improve wages, benefits, and conditions on the job.

Warehousing Education and Research 

Council (WERC)

http://www.werc.org

WERC provides leadership in the warehousing/

distribution field to advance the art and science 

of warehousing management. WERC supports the 

professional development of their members and 

the logistics community by providing quality learning experiences, and networking opportunities. 

SOURCES FOR INFORMATION FROM 

BUSINESS/LABOR TRADE ASSOCIATIONS 

*This listing is for identifying trade associations with members that are concerned with improving material handling. It does not mean these 

associations recommend adopting these solutions as presented.
18 • ERGONOMIC SOLUTIONS for Retailers

Anderson VP, Schulte PA, Sestito J, Linn H, Nguyen LS [2010]. 

Occupational fatalities, injuries, illnesses, and related economic loss in 

the wholesale and retail trade sector. Am J Ind Med 53(7):673–685.

Bhattacharya A, Leigh J [2011]. Musculoskeletal disorder costs and medical 

claim filing in the U.S. retail trade sector. Ind Health 49(4):517–522.

Cal-OSHA, NIOSH [2007]. Ergonomic guidelines for manual material 

handling. Sacramento, CA: California Department of Industrial Relations, 

Division of Occupational Safety and Health. Cincinnati, OH: U.S. 

Department of Health and Human Services, Centers for Disease Control 

and Prevention, National Institute for Occupational Safety and Health, 

DHHS (NIOSH) Publication No. 2007–131. http://www.cdc.gov/niosh/

docs/2007-131/pdfs/2007-131.pdf.

Lavender SA, Sommerich CM, Johnson MR, Radin Z [2010]. Developing 

ergonomic interventions to reduce musculoskeletal disorders in grocery 

distribution centers. In: Proceedings of the Human Factors and Ergonomic 

Society, 54th Annual Meeting. Thousand Oaks, CA: Sage Publications.

Liberty Mutual Research Institute for Safety [2012]. The 2012 Liberty 

Mutual workplace safety index: from research to reality. Hopkinton, MA: 

Liberty Mutual Research Institute for Safety.

Silverstein B, Adams D, Kalat B [2004]. Injured at work: what workers 

compensation data reveal about work-related musculoskeletal disorders 

(WMSDs). Washington State: Washington State Department of Labor and 

Industries.

REFERENCES

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through research and prevention.

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CDC-INFO: www.cdc.gov/info

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DHHS (NIOSH) Publication No. 2015-100

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