Policy Area: Occupational Health & Safety

G306-02 Minimum Warehouse Safety Requirements – Storage,

Guidance: Loading / Unloading and Internal / External Transport -- Global

Effective from: 1st Jan 2018

Revision & date: First version

Document owner: Group Safety

Confidential for internal Unilever use only – not to be copied

This document is the extract of Guidance on Warehouse Safety Storage, Loading

and Unloading and Internal and External Transport available in Global portal
http://inside.unilever.com/supplychain/sgc/Pages/Occupationalhealthsafety.aspx
Contents

GENERAL GUIDELINES

1.0 Introduction

2.0 Scope

3.0 Types of Warehouses

3.1 Traditional warehouses

3.2 Storage of Dangerous and Hazardous Substances

4.0 Site – Design And Layout

4.1 Design and Layout

4.2 Building & Hardware
4.3 Electrical Safety in Warehouses
4.4 Layout
4.5 Fire-fighting equipment

5.0 Warehouse Management Systems, Hazards & Controls

5.1 Visual Controls / Safety Signs and Devices

5.2 Working at Heights
5.3 Personal Protective Equipment
5.4 General Housekeeping
5.5 Hygiene, Cleaning & Pest Control - GMP

6.0 Equipment / Vehicle Selection, Operations and Maintenance

6.1 Safe Vehicles

6.2 Transport of Goods – Material Handling Equipment
6.2.1 Forklift Trucks
6.2.2 Reach Truck
6.2.3 Pallet Truck
6.2.4 Hand Pallet Truck
6.2.5 UPS / Battery Charging
6.2.6 Refueling industrial trucks
6.3 Delivery Trucks Operational Safety Guidelines

7.0 People (Personnel / workers)

7.1 Access Control in warehouses

7.2 Marking of Roads/Passages
7.3 Movement of Vehicles in Restricted Areas during Loading and
Unloading Operations
7.4 Safe Procedure and Activities of the Driver and his/her Assistant
when Fixing Malfunctions
7.5 Work breaks

8.0 Personal Protective Equipment at Work

8.1 The hazards and types of PPE

8.2 CE Marking

9.0 General Guidelines

10.0 Incident Reporting

11.0 Audits

9.1 Objectives
9.2 Audit frequency
9.3 Requirements for audits

REFERENCE

Warehouse Audit Checklist

GENERAL GUIDELINES
Standard Document: Warehouse Safety – Storage, Loading / Unloading
and Internal / External Transport

1.0 INTRODUCTION

Unilever is committed to provide its consumers and customers safe and quality
products. To achieve this, it is essential that the transport, warehousing and
distribution of all materials, raw and packaging, and the finished goods are performed
in a way which maintains quality, environment protection and health and safety of
employees, service provider’s personnel and the public.

Warehousing covers a wide range of activities that can result in various hazards and
risk. Therefore, an effective health and safety management is needed to look into the
risks that may arise in the workplace and then putting sensible control measures in
place to address them. By doing so, most valuable assets, the people, the premises,
equipment, goods, employees as well as members of the public are protected from
harm including the reputation of the company.

This document is intended to help people who manage and supervise warehouse and
transport operations to reduce or totally eliminate injuries and occupational ill-health
in the workplace and while transporting goods.

This document also includes mandatory requirements on warehouse working

environment, hazard identification, risk assessment, provision of controls and how to
deal with accidents and emergencies. For requirements that are not specified here,
local legal requirements must be met.

This document will also be useful in the proper selection and periodic audits of
transport, storage and warehouse providers.

The requirements defined in this document are for Unilever Third Party Logistics
Service Providers and must not be disclosed to other third parties other than those
specifically designated by Unilever. Any contractor and / or sub-contractor must
meet the requirements set forth in this document. A regular safety inspection to
promote, ensure integrity of SHE management system and identify deficiencies has
to be established. The responsibility for the transported and stored goods remains
with the provider who signed the Unilever contract.

2.0 SCOPE

A warehouse is defined as a facility for the storage of finished products, raw and
packaging materials for use in the manufacture of a product. It could be located
inside a manufacturing site or at an independent establishment, either managed by
Unilever or a third-party service provider.

The scope of this document is limited to the storage of raw and packaging materials,
finished products, its loading and unloading and their transport internally or externally.
All warehouses in which Aerosols are stored will be covered under Purple and Red
Books requirements
Included within the scope of this document are the following warehouse features and
operational activities:

· Warehouse Design - Layout and Capacity

· Operations
· Material Handling Equipment / Transport Vehicles Operations
· Maintenance
· Transport of materials within and outside warehouses
· Modification / Changes to design, equipment or operations

This document is also applicable to:

 All primary and secondary transport routes, whether within the city limits or
across provinces, including movements within the warehouse premises.
 All Third Party Warehouses and Transport Providers and their sub-
contractors thereto.
 All types of distribution channels, depots, whether ambient, frozen, chilled
or otherwise.
 Any means of road transport used e.g. trucks, trailers, tankers, etc., and
motorized materials handling equipment (MMHE) e.g. forklifts, reach truck,
pallet movers and mechanical handling equipment (MHE’s) etc.

This guidance document is particularly relevant to warehousing and transport

operations where the size of the inventory and the intrinsic hazards associated with
the actual conditions of warehouse operations e.g. temperature, storage, contents,
rates of transfer / transport, etc., are such that a failure to properly control the
warehouse operations and the maintenance of means of transport and material
handling equipment and/or to control the subsequent modification in terms of
contents and capacities could potentially result in a major safety incident1.

Possible hazards in a typical warehouse include:

Injuries to people:

a) Injuries caused by collision of humans with vehicles – (trucks, fork-lift trucks

and stackers).
b) Injuries caused by bad ergonomics or improper work practices.
c) Fall from heights while stacking or removing materials from upper shelves.
d) Exposure to hazardous materials and energy sources, viz., Electricity, etc.

Damage to property and/or loss of material:

a) Minor material losses could occur due to poor handling.

b) In a mechanized operation, occasional major damages have been reported
due to FLT hitting storage racks.
c) A fire in a warehouse can result in major property & material losses and
resultant business interruptions. While the probability of a fire in a well
11
Major Safety Incident: An incident resulting in one or more fatalities, serious occupational
injuries/illnesses, a threat to the health and well being of the people working or living in the
nearby local community or any major fire, explosion, loss of containment etc., which could
foreseeably attract the sustained (> 1 day) interest of the national media or damage the long
term corporate reputation of Unilever or of one of its major Brands.
 managed warehouse is low, the losses due to a fire can be high if adequate
controls are not in place.
d) Loss due to structural failure
e) Collision of vehicles with other vehicles or stationary structures and building.

Some products of Unilever must be handled in compliance with the published

Unilever Specific SHE Standards e.g. Safe Handling of Enzymes and Aerosols.
(Refer to Corporate SHE database for more information on these and on other
products specific corporate guidance and good practice documents).

Selection of Warehouses and Service providers

Most organizations operate or outsource logistics operations wherein the warehouse

is designed to cater for their needs in terms of contents and capacities. The
organization is normally required to install the facility equipment safely with all the
necessary safety and fire-fighting equipment. Material handling equipment are either
owned or outsourced, its future maintenance and servicing to either the original
supplier or to a separate sub-contractor. In these circumstances, Unilever relies on
the competence of the supplier and maintenance/servicing company to provide and
implement an effective safety management system on their behalf. It is therefore vital
that these logistics providers, suppliers and servicing companies are very carefully
selected.

The document provides best practices in warehouse management and as such is

useful both for existing warehouses or new warehouses.

3.0 TYPES OF WAREHOUSES

In order to store materials Unilever uses various types of Warehouses which are
identified primarily by the material handling and storage systems.

 Traditional Warehouse

These warehouses would be characterized by non-palletized storage of materials

in individual low stacks primarily on the floor/tarpaulin sheets, absence of storage
racks with largely manual handling of materials.

 Temperature controlled warehouse

For Unilever operations, this would refer to storage of Ice Cream, Ketchup,
mayonnaise and its related products and any other product requiring temperature
control.

 Storage of Dangerous & hazardous substances

For Unilever this would cover aerosols and hazardous chemical raw materials.

 Modern Warehouse

A modern warehouse would normally have storage racks which store palletized
loads in high stacks (3 or higher), use mechanized handling of pallets through
forklifts or other such devices. These are normally large with clearly identified
loading bays with facilities to load materials largely mechanically on to trucks,
containers etc.
Given below are some key hazards in different types of warehouses as listed above.
The balance of the document will deal largely with Modern warehouses though many
of the systems mentioned there would need to be followed in all warehouses.

3.1 Traditional Warehouse

1) Handling of bags and boxes

a) Goods heavier than 50Kg (or as limited by local legislation if it is <50 Kg) shall
not be allowed to be lifted by a single person during loading / unloading and
stacking / un-stacking.
b) All such loads shall either be carried on shoulder back or in trolleys. It is
preferable to use hand trolleys for moving goods within the warehouse, rather
than carrying loads manually.
c) Unloading / loading on trucks and stacks:
 Safety belts shall be used at all times by people climbing onto the material
stacks in the truck for loading/ unloading. Provision for anchoring safety
harness shall be made above the truck loading/unloading point.
 Unloading of bags from the truck shall preferably be onto a bay at the
same level as the truck-bed. Alternatively, a smooth ramp of 15 deg
incline, fixed or portable, shall be provided for loaders for their movement
between truck and the bay.
d) Stacking & un-stacking
 Stacks shall be formed using inter-locking (honey-combing) method to
provide stack stability. Any stacked material above ground level, must be
either secured with tape or shrink wrap.
 The maximum height of a pallet with material should not exceed 2 meters
 Maximum stack height shall be as per the stacking norm for the specific
material, or applicable statutory rules, whichever is lower.
 Empty pallets stacked against the wall should not exceed a height of two
meters. There must be clear marking on the wall just above two meters,
which must be visible
 Safety belt shall be used if people have to climb over a stack of bag for
stacking / un-stacking. However this should be avoided as far as possible.
In any case no climbing shall be permitted over boxes / bags which can
damage material or cannot take the additional weight.
 Un-stacking must start only from the top. Un-stacking by pulling/removing
loads from intermediate/lower layers of a stack shall be strictly forbidden.
e) Drum handling
 No truck shall ever have more than a single layer of 200 liter and above
size drums stacked.
 Drums containing liquid shall be stored in a separate area so that liquid
spills, if any can be contained.
 Drums of 200 liter and above size shall be stored in a single layer. For
storage of smaller containers i.e. 25kg drums, stack shall not exceed 2
high if permitted by the drum design.
 Persons engaged in drum handling shall wear safety shoes at all times.
 Drums should be transported with help of a drum trolley.
 Loading and unloading of drums to/from trucks, if the truck floor is not at
ramp level, shall be done in either of the following ways: (a) lift trucks, (b)
chain pulley block or (c) rolled up/down a ramp using a rope harness
around the body of the drum
  Drums should never be dropped from a truck while unloading.
f) Storage of flammable material
 Aerosol, aftershaves, nail enamel / remover, perfumes etc. should be
stored in a segregated area.
 Aerosol storage must comply with the UL aerosol standard (comply with
purple book checklist).
 Prominent warning signs in local language shall be displayed at such
locations.

3.2 Storage of Dangerous / Hazardous Materials / Goods / Substances

Certain items of stock (and some chemicals used for cleaning) may be classified as
hazardous or highly flammable. Exposure to some of these chemicals through leaks
or spillages could cause burns, dermatitis or could be harmful if inhaled.

1) Flammable products like aerosols and nail polishes should be stored with
adequate segregation and their inventory should be kept at minimum possible
level. Storage and handling of aerosols must comply with the existing Unilever
standard for aerosol warehousing (comply with purple book checklist).
2) Separation of hazardous goods and other goods by a wall of at least 60 minute
fire resistance is recommended. They should be stored in a well ventilated room
(ventilation should be both at height and at ground level). Natural ventilation with
a fine wire mesh covering the openings is recommended.
3) Oils Packs (hair oils or edible oils, etc.) should be segregated from other
materials. In case of a leak the damaged material should be immediately removed
so that oil does not spread to other stocks.
4) Generator sets and fuel storage should be segregated from main building.

4.0 SITE – DESIGN AND LAYOUT

4.1 Design and Layout

Warehouses must be of adequate design, suitable for the conditions of operation and be
capable of maintaining the required standards during storage, loading and unloading,
including any specified temperature requirements. The following considerations must be in
place while designing a safe warehouse.

4.2 Building and Hardware

a) Ensure structural integrity of the warehouse and the racking system through
proper engineering design and sound construction by competent contractor.
Confirm the ‘code of practice’ used by the consultant in designing the system.
b) Subsoil investigation should be carried out at site before design to determine
Safe Bearing Capacity (SBC) of soil
c) and to check suitability of the excavated soil for filling in foundations, plinth,
etc. CBR values also need to be determined for road design.
d) Finished floor level should be above the highest flood level of the location.
e) Particular care should be taken while choosing the filling material for
foundation & plinth and its compaction to avoid sinking of floor.
f) While designing a high racking system, adequate consideration should be given
to earthquake potential at the site.
g) While ensuring protection of goods against rain and wind, efforts should be
made to maximize the advantage of natural light.
 h) Aisle should be adequate for safe driving and turning of Fork Lift Trucks. They
should be clearly marked to facilitate safe driving.
i) Protective railings / bars should be provided at all vulnerable areas (mainly
turning points) to protect the storage racks from moving/turning Fork Lift
Trucks.
j) Clearly specify maximum loads permitted (kg/m2 of floor and kg/pallet). These
should be known to operating personnel and ‘built-in’ to the warehouse
management system.
k) Permitted floor loading / rack loading should be prominently displayed.
l) Provide adequate lightning arresters for the warehouse buildings.
m) Adequate access should be provided for emergency services like fire tenders
around the warehouse.
n) The warehouse building must be sited in area that is substantially free from
objectionable odor, smoke, dust, and / or other atmospheric contaminants,
which may cause contamination of the products.
o) Construction: Building and services must be of sound construction and
weatherproof (no leakage or flooding of any sort). Adequate provision must
be made to prevent pest infestation and the entry of environmental
contaminants of chemical or biological nature.
p) Ventilation: To avoid build up of heat and humidity to unacceptable level,
ventilation has to be provided to ensure good flow of air - preferably naturally
and / or with exhaust fans.
q) Illumination: The warehouse should have enough lighting for keeping right
identification of the goods during storing and taking, and for helping the
general hygiene and tidiness maintenance of the warehouse. A minimum of
125 lumens lighting should be provided for the warehousing activity.
r) Special attention should be given to the design of loading / unloading areas e.g.
how FLT movement will take place, how truck beds will align with the platform
etc.
s) Hazardous goods, such as flammable liquids, aerosols, hazardous chemicals
and goods liable to spontaneous combustion must be stored with adequate
segregation from other stocks and from each other.
t) Stocks should be kept clear from potential ignition sources e.g. battery charging
area.
u) UL standard requires that above certain specified value of goods stored, the
storage area must be segregated from manufacturing area either by providing
a separate building or a 60 min fireproof wall.

4.3 Electrical Safety in the Warehouse

All electrical installations and maintenance practices in dedicated built to suit

warehouses must conform to Unilever electrical standard or local legislation
whichever is higher.

All electrical installations and maintenance practices in other shared warehouses

must at a minimum conform to local legislation.

4.4 Layout

Within the warehouse storage area, there should be separate walkways for human
traffic. These walkways – “Green paths”- should be clearly marked on the floors with
paint or tiling.

4.5 Fire-fighting equipment

Adequate assessment of fire risk should be carried out and fire protection system
should be provided in line with local legislation and UL standards.

5.0 WAREHOUSE MANAGEMENT, SYSTEMS, HAZARDS & CONTROLS

5.1 Visual Controls / Safety Signs and Devices

Signs should be placed so people have time to see and understand them, and take
any action to reduce risks before they reach the hazard. Make sure that signs are:

a) Clear and easy to understand;

b) Obvious enough to be noticed;
c) Clean and well maintained so that they are always visible;
d) Reflective and lit if they need to be visible in darkness.

5.2 Working at Heights

 Follow UL standard on Working at Heights.

 Forklifts and MHEs should not be used to hoist personnel. For periodic
stock verification, a safety cage of standard design must be used which
should be anchored and bolted on lift jaws of the lifting equipment and
must be securely locked by the person occupying it. The person must
further use a safety harness anchored on a safe point on the equipment.
Under no circumstances should the lift equipment be moved when the
person is hoisted at a height even inside such a safety cage. Before every
movement the person must be lowered almost to the ground level before
making a horizontal movement of the equipment.

5.3 Personal Protective Equipment

 Safety shoes, high visibility clothing, and safety helmet must be the basic
PPE requirement and shall be provided to all persons working in the
warehouse.
 Take into account the demands of the job when selecting PPE, consider:

1. The physical effort required to do the job;

2. The methods of work;
3. How long the PPE needs to be worn;
4. Requirements for visibility and communication; and
5. Compatibility of PPE where more than one item is required.

5.4 General Housekeeping

Safe Condition

 Never store flammables with combustibles. Keep separate storage for

flammables based on fire codes.
 Store fire-fighting equipment in a place where it can be easily accessed.

5.5 Hygiene, Cleaning & Pest Control - GMP

Fumigation & Disinfection

  Where appropriate, fumigation of empty containers with pest control
agents is permitted, provided each instance is approved by Unilever, and
only Unilever approved fumigants and legally authorized agents must be
used.

Pest Control

 A complete pest control management program must be in place and

maximum attention must be given to prevent pest occurrence.
 Due to the specialist nature of pest control, pest control must be carried
out by a professional third party company, duly authorized to perform
these duties.

Waste Management

 Waste should not be allowed to accumulate inside/outside the store.

6.0 EQUIPMENT / VEHICLE SELECTION, OPERATIONS AND MAINTENANCE

6.1 Safe Vehicles

General Requirements

 All vehicles shall comply with the Unilever safety requirements.

 All vehicles should be fitted with both rear and front safety belts.
 Vehicles fitted with one front safety belt should only be used to transport
the driver.
 It is mandatory for all vehicles to keep their watch lights on
 When reversing, vehicle backup lights and horn signal must be used at all
times.
 Fueling a vehicle with gasoline, diesel fuel, or propane must be done
outdoors. Ensure that the proper OSHA and fire regulations have been
followed. Observe all specific safety rules, including a no-smoking policy.
 Forklifts run by LPG are banned and must not be allowed in any
warehouse
 In the battery-charging area, protective clothing consisting of rubber
gloves, apron, and face shield must be available.

Driver requirements

 All drivers must be in possession of a valid driver's license.

 Every driver driving a powered vehicle must undergo defensive driving
training and a refresher at a predefined frequency.
 Routine medicals must be conducted annually to certify all drivers
medically fit to drive.
 Always wear a seatbelt.

Driver responsibilities

a) All drivers must comply to the following:

 Always check that the vehicle they will be driving is fitted with safety belts
 which must be worn at all times when driving.
 Full adherence to speed limits.
 Avoid all distractions whilst driving.
b) No drivers must be under the influence of drugs including alcohol while on
Unilever business. This includes any prescription medication that may have a
negative effect on a person’s driving capabilities.
c) Remove keys from the ignition when parked or exiting the vehicle. During loading,
the key must be kept with warehouse personnel in a secured place and handed over
back to the driver only after completion of loading and load is fully secured and just at
the time of removal of chokes.
d) Never indulge in stunt driving or horseplay.
e) It is the responsibility of the driver to ensure that the load being carried must
never exceed the vehicle's rated carrying capacity.

Pedestrian /people requirements

 All persons working in the warehouse including visitors must wear high
visibility clothing for example reflective vest.
 All persons found within the warehouse premises must ALWAYS wear safety
shoes at least S1 Class (toecap), including the drivers.
 All employees working in the warehouse must ALWAYS wear correct PPE.

General Safety

Operators shall not pass other trucks going in the same direction at intersections,
blind spots, or other dangerous location.

Equipment Safety

 Only one person shall be on each piece of powered equipment at a time- no

riders.
 Always wait for the powered equipment to come to a complete stop before
getting off.

Operational and Maintenance Safety

 Keep product stored at least 36 inches from roof sprinkler heads. Keep
loads clear of sprinkler heads when moving product so that they aren’t
struck. Damaged sprinkler heads could cause a major water leak.
 Use steps or ladders to gain access to dock wells; never jump off a dock.
 Be sure the dock plate and trailer floor are secure and sound before
entering the trailer. A pre-inspection of each trailer should take place prior
to loading.
 An overhead hoist, conveyor, or equivalent material handling equipment
shall be used for handling batteries.
 Both eye wash and body showers must be located in battery-charging
areas. Eye wash stations must allow for at least 15 minutes of eye flushing
satisfying the OSHA code.
 Always check both sides of the wheels of trailers and trucks before
entering them. It is the responsibility of the operator to check on this
safeguard. If the truck driver has not chocked the wheels, it is incumbent
on the operator to do chocking. If the driveway is slippery, constantly
check the placement of the wheel chocks.

Safe Loading Guidelines

  The load backrest extension shall be used whenever necessary to
minimize the possibility of the load or part of the load falling rearward onto
the operator.
 An elevated load must only be tilted forward when it is directly over a stack
racking or the location where the load will be deposited.
 Never raise or lower a load while the vehicle is in motion.
 Before lifting a load, ensure that the product is stable and secure, that the
load is within the capacity of the truck, that the pallet or container being
used is not defective, and that the size of the load allows it to be driven to
a prescribed location.
 Never overload the lift truck. The rated capacity is shown on an
identification plate permanently mounted on the truck. Keep loads within
the rated capacity.

Additional Guidelines

 When on a rider model, always come to a complete stop before getting

off.
 Always turn the key off when inspecting the pallet unit.
 When parked, lower the load and shut of the key.
 Remove the key to prevent unauthorized use of the pallet truck.

6.2 Transport of Goods – Material Handling Equipment

6.2.1 Forklift Trucks

Equipment

Increased Risk of Equipment Failure

 Racking structures, Fork lift trucks, Mechanical Handling Devices, etc. that
operate permanently in the cold, particularly at sub zero temperatures, may
require more period inspection and maintenance to identify any defects
caused by continual operation in the cold.
 Similarly, mechanical devices that use hydraulic fluids designed for operation
at low temperatures may fail if taken outside into normal ambient
temperatures due to viscosity changes in the hydraulic fluids. E.g. lifting and
braking mechanisms.

 Unless equipment is totally dedicated to the low temperature environment,

and can be prevented from unauthorized use in other locations, then the
operational temperature range of all hydraulic fluids must be checked to
ensure that this does not occur.

Refueling / Recharging

 For compressed gas driven forklifts, cylinder changes must be undertaken in

the open air and safe external cylinder storage must be provided.
 Diesel powered trucks must be refueled in the open air and the fuel must also
be stored in the open air.
  Beside this Unilever Standards, also FM Global typically recommends
keeping any electrical devices, including battery chargers, at least 2 m from
combustible storage, to avoid causing a fire in case of electrical fault.
 Take the following steps to limit the production of hydrogen and increase
battery reliability:
1. Provide battery chargers with overcharge protection.
2. Provide suitable ventilation.
3. Maintain the battery room or area as close to 77°F (25°C) as
possible.
 Keeping the battery chargers under an external dedicated canopy is
frequently the preferable option, as this solution does not present the problem
of having combustibles nearby, and the problem of providing sufficient
ventilation for hydrogen (this is a real problem if there are many lift trucks in
the same closed area).
 It is necessary to segregate battery charging area from aerosol and roll on
storage areas since they present an unusual fire risk because of being
electrical equipment. Otherwise the main emphases on electrical equipment
will to be to ensure that it is well maintained and kept in a safe operational
condition.

Training

 Forklift trucks and other motorized material handling equipment must only be
operated by qualified and authorized drivers (Certificate of Competency,
licensed and/or formal management authorization). Driver training (Certificate
of Competency, license and/or authorization) must be equipment specific and
repeated at least once every three years. Such training must include both
theory and practical driver assessment.
 Beside the license and/or authorization trainings which include practical
assessment, operators must have refreshment safety training at least once in
a year. Such training must be at least theoretical with verification of
understanding.
 Where aerosol products are stored or handled, fork lift truck drivers should be
trained in relation to hazards associated with aerosol products
 Training records must be kept.

Specification & Maintenance

 All forklift trucks and other material handling equipment must be suitable for
their intended use, serviced and maintained as defined by the supplier, and
subjected to a full safety check at least once a year, maintenance records
must be kept.
 Equipment used in stores with flammable liquids and gases must be suitable
to be used in these areas with regards to explosion risks.
 At least once per day the driver must check “Daily Checklist.xls” the Forklift
for obvious safety defects. A handing and taking over process must be
established between the shift operators. Any defect including collision must
be reported immediately
 Before purchasing or renting, “Mandatory Applications.xls” must be used &
checked to ensure that the new forklift is safe from the beginning.

Auditing

Safety Observation tour must be undertaken to warehouse areas and safety contacts
must be done with fork lift operators. Sites are encouraged to carry out specific
safety observations on Fork Trucks at least once a year. “Deep Compliance:
Forklift Truck Safety” checklist should be used and documented at least once a
year.

Recruitment – Choosing drivers / operators

 They should be fully able to operate the vehicle and related material handling
equipment safely, and should receive comprehensive instruction and training
so that they can work safely.
 They need to have the right attitude and be reliable for such operations.
 Safely operating most types of vehicle and other material handling equipment
needs a reasonable level of both physical and psychological fitness and
intelligence.
 They should be fit enough so that being in control of the vehicle does not
pose a risk to their own health and safety, or for others. Fitness for workers /
drivers / operators should always be judged individually. Some less physically
able people develop skills to compensate.
 Regular medical check as per the local guideline must be done for fitness. In
the absence of any local regulation, the driver must be tested for vision at
least once a year.
 The requirements of a particular vehicle, material handling equipment, task
and situation should match with the fitness and abilities of the driver /
operator.
 An example of a suitable level of fitness might be that people who use
industrial lift trucks should usually be able to fully move their whole body, to
allow them to maintain good awareness of hazards all around their vehicle.
 Employers, managers and supervisors should never allow anyone who is unfit
through drinking alcohol or drugs prescription or otherwise to work / drive any
vehicle or other material handling equipment.
 If the workplace has contractors working on site, the site operator or principal
employer should take measures to ensure that they are competent to carry
out their duties responsibly and carefully. They will be governed by the same
requirements as that of Unilever employees. An example might be asking for
evidence of their capabilities from the drivers or their employers.

Incident Reporting And Investigation

 Our goal is to have “Zero Knocks”. Every site must establish a robust incident
reporting process. Even minor collisions must be reported and investigated.
There is an “Example Collisions Record Template”. The lessons learnt
must be widely communicated to prevent recurrence. The sites are
encouraged to install the black boxes which can track the collisions and send
instant communication to supervisor. The site must track the performance of
each operator and have a disciplinary process to take of care of repeated
violations. The fork truck collisions have to be tracked and reported to the
site central safety committee at least on a quarterly basis. The site must
establish a reward process to reward consistent good performance.

Forklift Truck Handling

All forklift trucks must be of standard Unilever approved makes. Only battery-
operated fork lift trucks (FLT) should be used inside the warehouse. Batteries should
preferably be sealed and maintenance-free type.

 FLT should have a canopy on the top to prevent any possible injuries
due to falling material.
 Maximum permitted loading should be displayed on the Fork Lift Trucks.
 Ensure that daily pre-start checklist is completed before start-up of
operation.

 To mitigate the hazards of stability caused by the movement of the

material being handled, guidelines for ensuring stability should be
adhered to.
 The battery charging bay must comply with UL standard.
 The batteries must be inspected regularly to check/correct any loose
connection/electrolyte level.
 Servicing of Fork Lift Trucks and charging of FLT batteries should be
carried out in a segregated area.
 Never operate a malfunctioning lift truck. Properly secure the truck and
hang an “out of service” sign or tag on it.
 Always wear your seat belt when on a sit-down lift truck.
 Always look in the direction of travel with a clear view. In the case of
reverse driving with product, utmost care must be ensured that the
vehicle is fully segregated from other traffic. The reverse horn and light
must be working. The speed must be limited only 5km/hour during
reverse driving.
 Keep forks approximately 6 inches off the floor when traveling.
 Ensure the forks are wide enough when lifting a pallet; keep forks as
wide as possible for any load.
 When approaching corners or blind spots, or when going from a bright
area into a darkened area, stop, look, and sound the horn before
proceeding.
 Maintain the stability of the load.
 Use shrink wrapping and product banding for security and prevention of
collapsing of product.
 Never turn on a ramp. Be alert to potholes, drop-offs on roadways, and
other obstacles that could tip the truck. Never travel with an elevated
load because of the high potential for tip over.
 Use mirrors, signs alarms, and other warning devices to protect
pedestrians.
 Beware of the rear-end swing of the vehicle.
 In uneven surfaces, use the wheel chocks designed for the purpose. Do
not use lumber, rocks, concrete blocks, chunks of asphalt, or any other
non-approved chock device.
 Make turns smoothly; slow down for turns in advance.
 A fire extinguisher must be mounted on the lift truck if the truck must
operate outdoors or in remote areas.
 Never lift anyone on the forks. Many of the manufacturers of forklifts
strongly recommend that a lift truck not be used with a lifting cage so that
a worker can gain access to a working elevation. Utilize a scissors lift or
other suitable means of elevation. Follow all of the prescribed safety
rules if a person will be working aloft.
 Never modify or misuse a lift truck.
 When driving keep at least three truck lengths behind the vehicle in front
 of the truck.
 When traveling up a ramp, have the load leading; when going down a
ramp, have the load trailing. If a malfunction of the equipment occurs on
a grade and the lift truck must be parked, block the wheels and add a
sign or tag indicating what the problem is. Be sure to set the parking
brake lower the load to the floor, set the gears in neutral, and remove the
key.
 Never leave a truck unattended. When stopped, always park out of the
way, lower the forks until they are flat on the floor, apply the parking
brake, neutralize the controls, turn off the key, and remove it from the
ignition.
 Never drive up to an attended fixed object without asking the employee
to move first.
 If a portable dock plate must be used, allow a lift truck to put it in place at
the dock rather than manually handling it.
 Never allow employees to ride on loads or help to balance loads.
 Never allow employees to walk or work under suspended load.
 Where lift trucks are equipped with front-end attachments, the weight
allowed to be lifted must now be reduced per manufacturer’s guidelines.
 A powered industrial truck is considered unattended when the operator is
25 or more feet (8 Meters) away from the vehicle which remains in
his/her view, or whenever the operator leaves the vehicle and it is not in
his/her view.
 Users of powered industrial trucks shall comply with the
recommendations set forth by the lift truck manufacturer regarding the
care and use of the equipment.
 A safe distance shall be maintained from the edge of ramps or platforms
while on any elevated dock, platform, or freight car.
 Lift trucks shall not be used for opening or closing freight doors.
 Approach elevators slowly. Enter the elevator evenly and squarely after
the elevator car is leveled. Once on the elevator, lower the forks, set the
brake, neutralize the controls, and turn off the ignition.
 Operators shall not pass other trucks going in the same direction at
intersections, blind spots, or other dangerous location.
 All parts replacement on a powered industrial truck shall be replaced
only by parts equivalent as to safety with those used in the original
design.
 Never remove or alter any parts on the truck. Never tamper with a safety
device.

6.2.2 Reach Truck

 Reach trucks must be used for the loading that involves the arrangement
of supplies and finished goods on pallets that are inserted into tall shelving
structures.

6.2.3 Pallet Truck

 Use of correct PPE for hands and feet is required at all time when
operating these trucks.
 All operators must undergo a comprehensive safety operating training
before they operate this truck; this must be in line with the manufacturer’s
safe operating procedures.
 Once training has been achieved, operators must be issued with the
 authority to run this machinery.

Safe Operating procedures for a Pallet Truck

 Before using the pallet truck, the following main functions must be
checked:

Load wheels Gauges

Steering handle
“Belly button” reverse switch
Operating controls
Battery connections and cable
Horn
Load backrest and extension
Directional and speed controls
Load data plane
Safety signs and labels
Braking mechanism
Other safety and operating devices

 While operating, the operator must always face the direction of travel
 Never walk faster than the speed of the unit being operated
 Only one person must operate the unit at one time.
 No rides must be taken on the trucks; this rule must be fully enforced on
all trucks.
 To prevent being struck or having one’s foot run over by the truck, walk to
one side when the load is trailing the operator.
 Always be aware of the position of the load and forks.
 Be aware of floor surface conditions. Oil, sand, grease, ice, water, or any
other slippery substance can cause the equipment to skid or to be difficult
to stop. A rider-pallet can provide a greater hazard to the operator
traveling on a slippery surface.
 Allow for sufficient clearance when moving the pallet truck to avoid hands
being pinched.
 Keep hands, feet & other body parts confined to the running lines of the
rider-pallet truck.
 All recommended PPE must be worn at all times
 Sound the horn to alert others of the truck’s position and motion.
 Never speed; an empty pallet unit can tip over of traveling to fast while
negotiating a sharp turn.
 Never use a second piece of powered equipment to push, pull, or lift the
unit.
 Always be alert for wet floors, as well as oil and grease spots. Report all
noted spills immediately as the pallet truck will be more difficult to stop as
a result of reduced traction.
 To avoid collisions, come to a complete stop at all blind corners, stop
signs, and aisle intersections. Sound the horn where necessary.

Stacking Loads

 Never permit anyone to stand or walk under the load-engaging

mechanism of the pallet trucks. Keep the arms, hands, feet, legs and
hand away from the upright mast at all times.
 Stack product securely on the forks. Restack an unbalanced load before
 moving it. Loads that are not secured should be equipped with metal or
plastic banding or plastic shrink wrapping.
 Never overload the pallet truck. The manufacturer’s data plate identifies
the capacity. Capacity can easily be made more visible to all operators by
stenciling the numbers on the sides of the powered equipment.
 Keep loads stacked as low as possible. Overloaded pallet truck can easily
strike the top of a trailer while entering. Dislodged product can easily fall
back onto the operator or someone else.
 Allow for proper turning and positioning clearances when moving loads.
The stacked product can easily strike other product, racking, electrical
equipment, sprinkler piper, or parts of the building structure.
 Only raise the load high enough for adequate floor clearance. Never
travel with an elevated load. Never raise or lower a load while the truck is
in motion.
 Use care and caution when operating near sprinkler heads, water pipes,
electrical wiring, heaters, steam pipes, or any other fragile or dangerous
material or equipment. Pallet trucks do not have overhead guards;
therefore, the security of the load is important. Never remove the
protective backrest from the mast. This metal bracket device helps to
secure product from falling back onto the operator.

At the Dock

 Be sure the trailer’s wheels are chocked or the trailer is secured with an
automatic trailer restraint, while entering.
 Go slowly on dock boards and dock plates. Be sure they are secured
before traveling on them. In addition, the capacity of the dock plate must
allow for the weight of the pallet truck and the load being carried. The lip
of the dock plate should be fully extended onto the back of the trailer. The
trailer should be parked flush against the building with the engine turned
off.
 Keep clear of dock edges, especially with rider units. Never back up
toward a dock edge. Paint dock edges yellow to provide for a visual
warning to operators and pedestrians.
 Know and observe floor and trailer floor load limits. Properly inspect the
trailer floor for security before driving into the trailer.

Ranks and Inclines

 When moving a load up or down an incline, the load should be facing

uphill. When the unit is empty, the forks should be facing downhill at all
times.
 Never turn a pallet truck on a ramp or incline; the unit could easily tip
over.
 If the pallet truck breaks down on a ramp or any other sloped surface, the
wheels should be blocked to prevent movement.
 Place a warning tag on the operating handle to alert others of the
mechanical problems.
 Remove the key to ensure no one uses the truck.
Elevators

 If using a freight elevator, be sure that the combined weight of the pallet
truck and the load does not exceed capacity.
 While waiting for an elevator, keep your powered equipment parked at
least 6 feet away from the elevator.
  When driving into an elevator, drive in forks-first and center the pallet
truck and load in the space available.
 No one should be in an elevator when the pallet truck is entering or
leaving.

6.2.4 Hand Pallet Truck

Safe Operation Guidelines

 Always leave a one inch clearance between the floor and pallet when
lifting a load.
 Avoid moving loads up or down ramps.
 Do not carry riders on the truck.
 Never use one fork to lift a load.

6.2.5 UPS / Battery Charging

Safety Requirements for Battery Charging Area

 In sites with UPS installations, the UPS batteries shall be housed in a

separate designated area; this area should be at least 2M clear of the
stored goods and preferably segregated with a wall.
 Ventilation must be good.
 Cold store must never be used as a charging area due to its poor
ventilation.
 All charging area must be far away from other electrical equipment.
 Smoking or any other kind of naked flame must be prohibited in this area.
 FLT battery charging area must be designed in line with UL standards and
implement all actions recommended by FM Global or other Risk
Assurance audits.

Safety Requirements for Charging the Battery

 The charger should be switched off before the battery is connected or

disconnected from it, to avoid sparks.
 Where batteries have to be changed, e.g. in a double shift system, a safe
system of work should be in place.
 Only trained personnel must be allowed to change batteries.
 Always use the correct charging unit as specified by the vehicle/battery
manufacturer and follow the manufacturer's instructions.
 Always raise the battery cover to aid ventilation during charging.
 Correct PPE must be worn at all times e.g. acid-proof apron, gloves and
goggles or a visor.

6.2.7 Refueling industrial trucks

Safety requirements for the refueling area

 Areas used for refueling industrial trucks must be outside.

 The risks of fire must always be considered and mitigated before any
refueling takes place.
 Refueling should not take place where there is a likelihood of an
 accumulation of flammable vapour in the event of a spillage, rains, pits,
galleys etc.
 Use of LPG as a fuel is not recommended; all forklifts run by LPG should
be phased out before end of 2013.

6.3 Delivery Trucks - Operational Safety Guidelines

Truck movement within premises

 Lay down the rules for all truck movement.

 Clearly define routes for truck movements and enforce adherence.
Consider the following: entry, parking, loading/unloading points, exits, etc.
 Only the driver with a valid driving license must be allowed to move the
vehicle within the premises.
 Wheel chocks must be placed under the tires and ignition turned off
whenever the truck is parked (offloading and loading).
 Unless it has been impossible, it is now mandatory for all existing
warehouses to implement one-way truck movement within the premises.
 New warehouses being built MUST ensure that this rule is fully adhered to.

Reversing

 Where possible avoid reversing completely.

 If reversing cannot be avoided, routes should be organized such that the
possible need for reversing is extremely reduced and that the distance
that a truck can travel backwards is kept to a minimum.
 One-way system is a very effective way of dealing with the risk of
reversing accidents.
 Ring roads drive-through loading and unloading positions, & parking areas
with entrances and exits on either side are just a few examples of
measures which help to prevent the need for reversing.
 Reversing areas must be clearly marked for easy visibility.
 Signage to warn drivers and pedestrians must be clearly visible.
 All vehicles must be fitted with mirrors wide enough for driver to see all
blind spots.
 Signage alerting drivers of potential dangers during reversing must be
visibly displayed.
 Where possible draw guide rails on the road to assist drivers.
 Vehicles should have large enough windscreens (with wipers where
necessary) and external mirrors to provide adequate all-round visibility.
 Items should not be placed in the windscreen area or in the way of mirrors
or monitors, where they might get in the way of visibility from the driving
position. A good guide can be that the area of the windscreen that is kept
clear by the wipers should not be obscured, and nor should the side
windows.
 Keep windows and mirrors in clean and in good repair. As dirt or cracks
can make windows or mirrors less effective.
 Signaler/helper should be used where there is no other way to control
reversing risks.
 Signalers/Helper must be trained to assist the drivers when reversing. Use
certain hand signals, and employers must make sure that the correct
 signals are used.
 Both driver and helper must understand the signage used and all
employees involved must be aware of the signage used.
 It is important that hand signals are used consistently throughout the
workplace.
 Helpers need to be visible to drivers at all times, particularly in low-light
conditions, which should be avoided if possible.

 If drivers lose sight of a helper, they should know to STOP

IMMEDIATELY.
 Use of portable radios or similar communication system is recommended
where possible.
 If the driver is not able to see clearly behind the vehicle for any reason,
they should apply the brakes and stop the engine, leave the cab and
check behind the vehicle before reversing.
 Segregating pedestrians and vehicles to improve pedestrian safety during
reversing.

Parking

 Build designated parking areas in the workplace. Ensure that these areas
are:
 Level & well lit;
 firm;
 clearly marked and with safe walking areas;
 easy to find; and
 As close as possible to where people need to go when they leave their
vehicles.
 Parking at any other area must be prohibited as it can introduce
unnecessary hazards.
 Full brakes must be applied when parking all vehicles, engines must be
stopped, and all load or mounted equipment must be lowered to the
ground.
 Where vehicles have to be parked on a slope:
 All brakes should be applied;
 The vehicles should be left in gear (if it is safe to do so);
 Wheel chocks or stops should be used in all cases even if parked on a
flat road.
 Vehicles should usually be parked facing up or down the slope, not
side on.
 Always lock away the keys of vehicles left parked in workplaces
overnight, at weekends or when they are being left for long periods.
 When trailers are parked, drivers need to make sure that both tractor
unit and semi-trailer parking brakes are used. Signage, instructions
and any other measures should be displayed or communicated to
make sure this happens.

Trimming, Sheeting & Netting

Some loads will need trimming to make sure they are well balanced and ready to be
transported, or before they can be sheeted or netted. Trimming is often needed
where bucket or hopper loading has left a load unevenly spread in the vehicle
container. Trimming a load can involve climbing to a height that makes accessing the
load possible, but as usual should not need anyone to actually walk on a load if this
can be avoided. There are a number of reasons you may want or need to cover a
load, and sheeting or netting is often a good way of doing this. Some materials may
need to be kept hot while being transported, such as bitumen or asphalt. Other loads
need to be kept dry, such as quicklime or some other powders. There are also legal
duties to cover some types of load to:

 Protect the environment;

 Prevent them from being a nuisance when you go onto public roads (for
example, material being blown off);
 Keep them safe.
 Loads need to be properly secured, and sheets or nets might be part of
the way you do this. Adhere to procedures for working at heights whilst
conducting these activities. Sheeting, netting or removing sheets or nets
can be dangerous, especially when it is carried out by hand, exercise
caution and use life lines
 No one is allowed to walk on loads, bags or pallets.
 If sheeting or un-sheeting happens somewhere windy, gusts can catch
sheets or knock workers off balance, exercise extreme caution

7.0 PEOPLE (PERSONNEL / WORKERS)

7.1 Access Control in the Warehouse

Vehicle entrance and exit area

When entering the premises, the vehicle driver shall have the following documents:

 Documents pursuant to the legislative requirements and verification about

his/her professional Driver’s training;
 Driver’s Trip Ticket (the so-called Stazka or possibly also LLRP, Delivery
notes, CMR, AAD, ADR);
 Valid driving licenses for motor trucks (if he/she wants to use it);
 Duly completed document called Vehicle Inspection corresponding to the
given transported cargo.

When entering the premises, the vehicle driver shall be equipped with the
following Personal Protective Equipment (PPE)’s:

- Protective work footwear (safety shoes with steel toe);

- Protective reflective jacket / vest
- Protective five-finger, working gloves
- Hard hat

Rules for providing vehicle / material handling equipment keys

Every driver / operator who is receiving a key from a vehicle for conducting
transportation activities for the Logistics Provider have the appropriate driving
license / accreditation for driving the given vehicle / material handling equipment.

7.2 Marking of Roads/Passages

Work site marking

a) The road and passageways are clearly marked by horizontal marking and the
traffic is organized by vertical traffic signs.
 b) Car park and parking lots for cars and trucks are marked by horizontal and
vertical traffic signs.
c) Work site markings and traffic signs should be reflective.

7.3 Movement of Vehicles in Restricted Areas during Loading and

Unloading Operations

Manner of moving the vehicle and reverse driving

Driving the vehicle on the warehouse premises is governed by the road traffic rules.
The maximum speed shall be as specified in site rules though a maximum speed of
15 km/hour is recommended. Prior to driving in reverse, the driver shall seek the help
of his assistant / helper (where available) who is obliged to make sure that the area to
where he wants to drive the vehicle is free and without any obstacles. This assistant
should be qualified, a competent and appropriately trained person. His function is to
assist and guide his driver of his maneuvers and reverse driving. Both driver and
helper are properly trained and familiar with the signals (hand or other means) given
by the helper while the driver is maneuvering inside the premises. Prior to any
reverse driving, the driver is obliged to give an audible signal. In some countries the
driver has this qualified helper who goes with him in every trip. In a few countries the
driver is alone on the vehicle and no helper is there. In such cases the driver should
ensure that there are no obstructions to the reversing maneuver particularly in the
blind spots and then reverse using the rear view mirrors. If the reversing has to be
done in a busy area help of the site security personnel should be taken to stop
personnel from entering the reversing zone.

Entering and leaving cargo area of the vehicle

If the cargo area of the vehicle is entered directly from the road, this procedure shall
be conducted using exit stairs or ladder.

Inspecting the connection of the trailer to the truck and inspecting the trailer
after it has been disconnected from the truck

Every driver shall be responsible, pursuant to the road traffic rules, for a safe
connection of the trailer to the truck, for placing and anchoring the cargo, for
complying with the prescribed cargo weight and also for securing (by means of
placing an A-frame as support) the disconnected trailer at the car park.

7.4 Safe Procedure and Activities of the Driver and his/her Assistant when
Fixing Malfunctions

Every driver whose vehicle breaks down on the road shall be obliged to:

- Secure the vehicle against spontaneous movement (provision of wheel

chokes);
- Mark the standing vehicle using blinking hazard lights and by placing the
emergency triangle to the appropriate distance from the vehicle;
- Wear the prescribed reflective jacket / vest the entire time when he is moving
around the broken vehicle.

7.5 Work Breaks

Maximum continuous driving time

The rules for continuous driving time, driving breaks and rest periods shall be
governed by local Labor law and / or Unilever Guidelines on Safe Travel.

The continuous driving time should not exceed 2 hours. Any breaks in driving shorter
than 15 minutes shall be considered driving time.

Driving should be interrupted after 2 hours of driving, at the latest, by a safety break
of at least 10 minutes.

8.0 Personal Protective Equipment

8.1 The hazards and types of PPE
8.2 CE Marking

8.1 The hazards and types of PPE

Eyes

Hazards: Chemical or metal splash, dust, projectiles, gas and vapour, radiation.
Options: safety spectacles, goggles, face-shields, visors.

Head

Hazards: Impact from falling or flying objects, risk of head bumping, hair
entanglement.
Options: a range of helmets and bump caps.

Breathing

Hazards: Dust, vapour, gas, oxygen-deficient atmospheres.

Options: disposable filtering face-piece or respirator, half or full-face respirators, air-
fed helmets, breathing apparatus.

Protecting the body

Hazards: Temperature extremes, adverse weather, chemical or metal splash, spray

from pressure leaks or spray guns, impact or penetration, contaminated dust,
excessive wear or entanglement of own clothing.
Options: Conventional or disposable overalls, boiler suits, specialist protective
clothing, e.g. chain-mail aprons, high-visibility clothing.

Hands and arms

Hazards: abrasion, temperature extremes, cuts and punctures, impact, chemicals,

electric shock, skin infection, disease or contamination.
Options: gloves, gauntlets, mitts, wrist-cuffs, armlets.

Feet and legs

Hazards: Wet, electrostatic build-up, slipping, cuts and punctures, falling objects,
metal and chemical splash, abrasion.
Options: Safety boots and shoes with protective toe caps and penetration-resistant
mid-sole, gaiters, leggings, spats.

8.2 CE marking

Ensure any PPE purchased is ‘CE’ marked and complies with the requirements of
the Personal Protective Equipment Regulations. The CE marking signifies that the
PPE satisfies certain basic safety requirements and in some cases will have been
tested and certified by an independent body.

9.0 General Guidelines

9.1 Operations

 Where possible, pedestrian and forklift truck routes must be separated.

Where people and forklift trucks cannot be separated, adequate measure
must be taken to ensure pedestrian safety (e.g. proper alert signs, the
wearing of high visibility jackets, the use a reversing alarm system, if not fitted
to the forklift truck beep twice and look in the direction of travel and/or the
replacing of motorized forklift truck with manual lifting ones in the areas
concerned).
 Loading and unloading areas and traffic routes must be kept clear of
obstructions and the road surface kept level, dry and non-slip where possible.
 Mobile phones and other communication devices must only be used while the
FLT is stationary.
 Pedestrian crossing places must be well marked. In areas of high FLT traffic
movement vehicle routes and junctions must be clearly marked to help avoid
collisions.
 Define the warehouse aisles as one-way where possible to minimize the
collisions.
 Where permitted by the sites Quality / Hygiene rules, Operators must carry a
copy of their Certificate of Competency*, license and/or authorization when
driving a workplace vehicle / material handling equipment.
 “1 meter - 2 meters” rule must be applied by all sites:

Both forklift operator and pedestrian should stop;

when the distance comes to 1 meter between the pedestrian and a moving forklift &
when the distance comes to 2 meter between the pedestrian and a forklift when the forks
are at height

9.2 Neurological Disorders, Psychological Conditions:

Cold store operatives should be emotionally stable and psychologically alert - many
will be fork lift truck drivers and must meet the health standards required for this
occupation. Cold stress may add to any reduction of concentration particularly
towards the end of a shift. Disease / disorder contraindications are for health and
safety reasons.
 Epilepsy - drivers must meet National Health requirements and extreme
caution is advised for non-driving cold working environment jobs.
 Blackouts - as for epilepsy above.
Peripheral neuropathy

9.3 Safety requirements in cold storage

9.3.1 Definitions of Low Temperature Working Environments

As already stated, this document is intended to cover controlled low temperature
working environments. Some examples of which are defined as follows.

9.3.2 Chilled Workrooms

The maximum temperatures of workrooms in which temperature sensitive foods are
handled are often dictated by food hygiene legislation, and more often than not this is
in contrast to the legal minimum working temperature, where one exists. Therefore
the Legislation for both must be satisfied by either protecting the foodstuff from the
warm ambient air by provision of local chilling, providing a warm working station
within a chilled room, or keeping the individual warm by the provision of suitable
insulated clothing.

Typical examples of maximum workroom air temperatures, and product

temperatures, mandated by the EC1 legislation are as follows;

Product Type Air Product

Temperature Temperature

Fresh Red Meat & Large Farmed Game - 12°C 7°C

Offal - 12°C 3°C

Meat products - 12°C 8°C or 5°C

9.3.2 Ice Houses/Cold Stores/Refrigerator Rooms/Walk in Freezers

Local interpretation of what is meant by a “cold store” etc., together with the variable
temperatures at which these locations are operated due to the requirements of the
process, or legislation, make exact definition difficult. Thus, when considering these
locations with respect to exposure and exposure control it is far better to consider the
temperatures involved, rather than the “name” applied to the area.

In general, the temperatures involved vary from +4 °C down to as low as -35 °C.
However, this range should not be taken as exclusive. Lower temperatures may be
encountered in some storage areas.

9.3.3 Freezing Tunnels/Blast Freezers

These are process plant used for continuous freezing of foodstuffs such as
vegetables, rice etc. Entry may be required during operation to clear blockages or
frozen deposits. They are significantly different from low temperature storage areas
in that the air velocities used within the tunnels are normally very high resulting in
significant Effective Corrected Temperatures caused by Wind Chill, and there is also
the risk of eye damage from airborne ice crystals or other debris.

1
European Commission
* Certificate of Competency : is kind of a licence given to employee by site or a site approved company that shows the
employee has the approval to use the equipment.
** This section must be assessed by legal departments in each country as it may constitute discrimination.

9.3.4 Medical assessment

 Pre-employment and pre-placement health screening of prospective cold
store workers is mandatory unless otherwise mandated differently by the local
legal requirements, because of the physiological stress caused by very low
temperatures. This will, of course, be minimized by the provision of suitable
protective clothing, the use of heated cabs on fork lift trucks, physical activity,
an optimum calorie and fluid intake, and physical and psychological fitness
9.3.5 Ammonia
 Devise a clear emergency procedure to be followed should refrigerant be
accidentally released, which includes evacuation, rescue, first aid, plant
isolation, etc
9.3.6 Working Condition
 Ensure persons required to work in very cold conditions do not suffer from a
medical condition likely to be made worst by the temperatures. Ensure that
employees do not spend more than 45 mins continuously with a minimum of
15 mins break before resuming work in cold stores

9.3.7 Protective Clothing & Insulation

Optimum thermal comfort requires the balance of three factors;
 Rate of metabolic heat production
 Insulation value of the clothing
 Environmental temperature

9.3.8 Specific maintenance requirement for equipment in cold stores

Sites to determine with expert recommendations types of equipment and its
maintenance program which is suitable for such condition

10.0 Incident Management

All 3Ps must have a process on managing incidents and gathering SHE statistics monthly.
All serious SHE occurrences as defined in S220-Functional SHE Standard -
Notification and Reporting of Serious SHE Occurrences and fatal incidents must be
reported within 24hrs.

11.0 Audit

11.1 Audit objectives

An audit is a systematic and independent examination to determine whether activities

and related results conform to planned arrangements and whether these
arrangements are implemented effectively and are suitable to achieve the Unilever's
safety policy and objectives. All 3P distributors are required to be audited and
recommendations from the audit to be rectified. An action plan must be prepared
after receiving the final audit report. This plan will include timings and responsibilities.
The accountability for compliance of the actions lies with the 3P distributors.
Independent auditors can be from internal Unilever or external 3P auditing firm.

11.2 Audit requirements

The entire SHE management system should be the scope of the audit with specific
focus on Fire, Electrical, Material Handling Equipment (MHE) and Emergency
Responses
All audits, at the minimum are to comply with local standards and in addition from
OSHA and Unilever standards.

11.3 Frequency

At minimum, all 3P logistics/distributors are to be audited once in every 3 years by an

independent competent auditor. The responsibility for the audit programs lies with 3P
service provider. Unilever has got responsibility to ensure quality audit is carried out
and actions are closed out timely. Self-assessment must be carried out yearly using
the checklist by the 3P.

Reference

Global Warehouse Audit Checklist