Product Overview

Summary: This Packing and Unpacking Safe Operating Procedure sets out safe, efficient and consistent methods for preparing, handling and opening goods in Australian workplaces. It helps businesses control manual handling risks, protect workers from injury, and maintain product quality from receipt through to dispatch.

Packing and unpacking activities are at the heart of many Australian businesses, from warehouses and distribution centres to offices, retail stores and construction sites. They also present a high risk of musculoskeletal injuries, cuts, crush incidents and product damage when carried out without a clear, safe system of work. This Packing and Unpacking SOP provides a structured, step‑by‑step approach that integrates WHS best practice with operational efficiency, ensuring that every item is handled correctly, labelled accurately and moved safely.

The document outlines standard methods for preparing work areas, assessing loads, selecting appropriate handling equipment, and using correct lifting and carrying techniques. It also addresses safe knife use, pallet and carton management, stacking and storage requirements, and procedures for unpacking fragile, hazardous or high‑value items. By implementing this SOP, businesses can reduce manual handling injuries, improve stock accuracy, minimise transit damage and demonstrate due diligence under Australian WHS legislation. The result is safer workers, fewer disruptions and a more professional, reliable packing and unpacking process.

Key Benefits

• Reduce manual handling injuries by standardising safe lifting, carrying and load‑handling techniques.
• Improve efficiency and consistency in packing and unpacking tasks across teams and shifts.
• Minimise product damage and stock loss through clear instructions for packing integrity and unpacking care.
• Ensure compliance with Australian WHS duties for hazardous manual tasks and safe storage of goods.
• Streamline induction and refresher training with a clear, documented procedure for everyday handling tasks.

Who is this for?

• Warehouse Managers
• Storepersons
• Logistics Coordinators
• Removalists and Relocation Teams
• Retail Stock Controllers
• Production Supervisors
• Office Managers overseeing relocations
• WHS Advisors and Safety Officers
• Inventory and Supply Chain Managers

Hazards Addressed

• Musculoskeletal disorders from repetitive or awkward lifting, carrying and twisting
• Back, shoulder and knee injuries from handling heavy or bulky items
• Cuts and lacerations from knives, box cutters and sharp packaging materials
• Crush injuries from unstable stacks, falling loads or incorrect pallet handling
• Trips and slips caused by packaging debris, strapping, shrink wrap and obstructed walkways
• Strains from overreaching into racking, vehicles or containers
• Exposure to hazardous substances when unpacking chemical or hazardous goods
• Hand and finger injuries when opening strapped or banded loads

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required PPE, Tools and Handling Equipment
• 6.0 Pre‑Start Checks and Work Area Preparation
• 7.0 Manual Handling Risk Assessment for Packing and Unpacking Tasks
• 8.0 Safe Packing Procedures (Cartons, Crates, Pallets and Containers)
• 9.0 Safe Unpacking Procedures (Receiving, Opening and Inspecting Goods)
• 10.0 Use of Knives, Cutters and Strapping Tools
• 11.0 Stacking, Storage and Housekeeping Requirements
• 12.0 Handling Fragile, Heavy or Irregular Loads
• 13.0 Handling Hazardous or Sensitive Goods (e.g. chemicals, electronics)
• 14.0 Incident Reporting, Near Misses and Damage Control
• 15.0 Training, Competency and Supervision
• 16.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Hazardous manual tasks and general workplace management
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• AS 4084: Steel storage racking
• AS/NZS 2161: Occupational protective gloves
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)