Lacerations from bandsaws are among the most common injuries in the meat processing industry, but importantly,
they’re also among the most preventable. With solutions such as BladeStop systems and the like, long-lasting blades, ongoing training, and fostering a vigilant safety culture among staff, operators can significantly reduce risks and ensure meat-processing safety while maintaining productivity at its highest level.
SAFETY WHERE IT COUNTS
In the boning room or out on the factory floor, few tools are more essential – or demand more respect – than the bandsaw. In abattoirs and meat processing facilities, these machines are vital, but their risks are real.
“Hand and forearm lacerations are the most common,” says Neil Holmgren, Business Development Manager at Bunzl. “But we’re seeing injury rates drop as innovation and awareness continue to reshape how safety is approached across the industry.”
SMALL CHANGES, MAJOR IMPACT
Arguably, the biggest advancement right now is the BladeStop style. Most abattoirs and meat processors now use this system on their saws. This requires the operator to wear a cable connecting them to the system, like a safety switch, and they need to wear a specific blue coloured glove. An electronic eye on the saw can detect if the blue glove touches the blade and instantly stops the blade with a brake. This system has reduced injuries dramatically and has all but eliminated serious injury.
As an innovation, it really does highlight just how practical engineering controls, rather than reactive policy, can cause measurable safety outcomes. But the impact of this type of system ultimately depends on how it’s used and how accountable those responsible are.
THE VALUE OF VIGILANCE
“It is imperative the operators are still 100 per cent focused and are wearing the correct PPE to make this work,” says Holmgren. “The floor supervisors are constantly watching to make sure these things are happening with all the equipment.”
This is a level of vigilance that’s backed by research in the Making the Meat Industry a Safer Place report, which found that a strong organisational focus on compliance, supervision and especially return-to-work policies can greatly reduce claims costs.
“If the blades are too dull, it forces the operator to use
more force, which is a leading cause of injuries.”
BLADE QUALITY MATTERS
Another key element in injury prevention is the condition and sharpness of the blade itself. A well-maintained, sharp blade allows for cleaner cuts with less effort, reducing strain on the operator and lowering the risk of slips or sudden movements that can lead to injury. “The blades on the saw must be regularly changed,” explains Holmgren. “If the blades are too dull, it forces the operator to use more force, which is a leading cause of injuries.”
Using high-quality blades designed for durability and long-lasting sharpness can make a huge difference in supporting safer handling, but also in helping maintain efficiency across shifts. Keeping a close eye on blade wear and building routine blade checks into safety protocols are simple, proactive steps that pay off in both performance and protection.
LOOKING TOWARDS A SAFER STANDARD
While no single solution will ever eliminate all risk, having a combination of modern equipment, structured training, PPE, and a committed leadership team is the best way to weave together a strong safety net. As Holmgren states with his trio of mustdos: “Proper training, proper PPE, 100 per cent focus.”
When all of these elements align, the path forward becomes much sharper and in greater focus. A smarter and safer future for meat processors across ANZ is absolutely within reach.
