Safe manual handling of imported goods
Assess how each packed unit will be unloaded, moved and unpacked at your receiving site before approving factory packing. Agree gross pack weights, usable grip points and any smaller packs or mechanical handling arrangements in writing. Share the agreed packing brief with Cambridge China Bridge.
Start with the receiving site's handling assessment
Employers must assess the risk of injury from hazardous manual handling that cannot be avoided. HSE advises considering the task, load, working environment and individual capability. Map the actual route from delivery vehicle to storage and unpacking, including carrying distances, repeated lifts, awkward reaches and the equipment available.
Ask the receiving team to review a representative packed sample before approval. Include any warehouse contractor in the discussion and identify who will approve the handling method. Use the container delivery checklist for delivery access and unloading arrangements.
Specify individual gross pack weights
The law does not set specific weight limits for manual handling. A carton weight alone cannot establish whether the task is suitable. Ask the factory for the gross weight and dimensions of each carton, bundle or crate that people will handle, including its contents and protective packaging.
Set your packing limits from the receiving site's assessment. Distinguish the weight of a complete pallet from the individual packs removed from it. Ask for weighed packed samples rather than estimates, and flag packs with uneven weight distribution or contents that can shift.
Check grip points with the pack fully loaded
Ask for photographs and a sample showing where hands can grip the loaded pack. Check that handles or hand openings remain accessible after wrapping and that the intended gloves fit. Look for sharp edges, slippery surfaces, collapsing cardboard and loads that block the handler's view.
Do not assume straps, decorative handles or carton cut-outs can support the load. Ask the factory to demonstrate the intended grip on a representative loaded sample. Agree reinforcement, better handholds or a different handling method where the proposed grip is unsuitable.
Agree changes before factory packing
Record the approved pack weight, dimensions, contents, grip design, weight markings and pallet arrangement in the purchase specification. Consider smaller packs, fewer items per carton or a layout that allows mechanical handling. Reassess the task after changes: lighter cartons can still create repeated lifting or awkward reaches.
Name the person who approves changes and require written agreement before the factory substitutes cartons or changes pack quantities. Keep photographs and the approved sample with the product specification. Check that handling changes preserve protection in transit using the packaging test guide.
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Verify packing and prepare the arrival handover
Before dispatch, ask for evidence that production packs match the approved sample: measured gross weights, dimensions, accessible grips and the agreed pallet layout. Send the receiving team the packing details and planned handling method before delivery.
If packs arrive heavier, damaged or differently arranged, pause the affected handling task and review how it can be done safely. Record the discrepancy and agree corrective action before repeat orders. Use the goods-in acceptance guide for the wider receipt checks.
Frequently asked questions
What is the legal maximum carton weight?
The law does not set specific manual handling weight limits. Agree pack weights from an assessment of the actual task, load, workplace and people handling it.
Should I use product weight or packed weight?
Use the gross weight of the unit people will handle, including the carton and protective packaging. Ask the factory to weigh a representative finished pack.
Do carton handles make a heavy pack safe?
Handles can improve grip, but assess the whole task. Check their strength, accessibility and suitability with the loaded pack and the gloves used at your site.
When should I agree packing changes?
Before approving factory packing. Record the changes, approve a representative sample and check production packs against it before dispatch.