Product Overview

Summary: This Secure Packaging Methods Safe Operating Procedure sets out clear, practical steps to safely package products, materials and equipment for storage and transport. It focuses on preventing injuries, product damage and load failures while supporting compliance with Australian WHS duties and chain of responsibility obligations.

Secure packaging is a critical control point in the supply chain, directly affecting worker safety, product integrity and customer satisfaction. Poorly packaged goods can shift, collapse or spill, creating crush, trip and manual handling hazards for workers in warehouses, vehicles and at customer sites. This Secure Packaging Methods SOP provides a consistent, WHS-focused framework for selecting packaging types, preparing items, and securing loads so they can be handled, stored and transported safely across Australian operations.

The procedure sets out step-by-step instructions for packaging a wide range of items, including fragile, sharp, heavy, irregular or hazardous products, and integrates with manual handling and traffic management controls. It supports businesses to demonstrate due diligence under WHS laws and Chain of Responsibility requirements by documenting how packaging risks are identified, controlled and verified before goods leave the premises. By standardising secure packaging methods, organisations can reduce injuries, minimise product loss and claims, and improve efficiency in warehouse and dispatch workflows.

Key Benefits

• Reduce manual handling injuries by defining safe ways to package, lift and move different product types.
• Minimise product damage and freight claims through consistent, fit-for-purpose packaging methods.
• Ensure compliance with WHS and Chain of Responsibility obligations for safe loading and securing of goods.
• Standardise packaging practices across shifts, sites and contractors for predictable, high-quality outcomes.
• Improve operational efficiency by providing clear, visual guidelines that shorten training time for new staff.

Who is this for?

• Warehouse Managers
• Storepersons
• Dispatch Coordinators
• Logistics and Transport Managers
• Production Supervisors
• Forklift Operators
• Pick and Pack Team Leaders
• WHS Managers and Advisors
• Inventory Controllers

Hazards Addressed

• Manual handling injuries from lifting, carrying or repositioning poorly packaged items
• Crush and impact injuries from collapsing pallets, cartons or unstable loads
• Trips and falls caused by loose packaging materials and spilled contents
• Cuts and puncture wounds from sharp or exposed product edges and strapping
• Struck-by incidents from shifting loads during forklift operation or vehicle loading
• Exposure to hazardous substances due to leaking, ruptured or unsealed containers
• Musculoskeletal strain from repetitive or awkward packaging tasks
• Vehicle load shift leading to rollovers or load loss during transport

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Standards and Definitions
• 3.0 Roles and Responsibilities
• 4.0 Risk Management and Pre‑Packaging Assessment
• 5.0 Packaging Material Selection and Minimum Standards
• 6.0 Secure Packaging Methods for Standard Cartons and Parcels
• 7.0 Secure Packaging Methods for Palletised Loads
• 8.0 Packaging of Fragile, Sharp, Heavy or Irregular Items
• 9.0 Packaging of Hazardous or Leaking-Prone Products (Non-DG and DG Interface)
• 10.0 Labelling, Weight Marking and Handling Instructions
• 11.0 Integration with Manual Handling and Forklift Operations
• 12.0 Inspection, Verification and Sign‑off Prior to Dispatch
• 13.0 Non‑Conforming Packaging and Corrective Actions
• 14.0 Training, Competency and Supervision Requirements
• 15.0 Recordkeeping and Continuous Improvement
• 16.0 Review, Audit and Document Control

Legislation & References

• Work Health and Safety Act 2011 (Cth and state/territory variants)
• Work Health and Safety Regulation 2011 (Cth and state/territory variants)
• Heavy Vehicle National Law – Chain of Responsibility (where applicable)
• Safe Work Australia – Model Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Model Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace (where applicable)
• Safe Work Australia – General Guide for Workplace Traffic Management
• AS 4068: Flat pallets for materials handling
• AS/NZS 4024 series: Safety of machinery (for interface with packaging equipment)
• AS/NZS ISO 31000: Risk management – Guidelines