'Off the Shelf' Manual Handling Training DVD Production
Case Study

Have you watched the Childs Play Manual Handling video? What are your thoughts on it? If you google search provision of Manual Handling DVDs you will find most (if not all) offer a production that only teaches lifting technique with some averagely presented information about manual handling laws and back anatomy/ injury.

At Osteopathic Solutions, we wanted to offer the UK market something different, something unique, something new, something better. A DVD full of useful practical manual handling content. A DVD that will teach. A DVD that will engage. A DVD of the highest production quality. A DVD that will reduce your manual handling lost time accidents.

As the 4 most common industries (to manual handling tasks) across the UK are Manufacturing, Food Production, Distribution & Logistics and Councils we decided that filming in these settings would offer the highest quality Manual Handling Training DVD.

After putting our project out there to our clients, the following came forward allowing us to film at their sites, with Osteopathic Solutions providing the finished production free of charge for them.

Pork Farms (owned by Addo Food Group) are bakers of delicious Classic Pork Pies and Melton Mowbray Pies made with 100% British Pork. Our team of Manual Handling Experts have provided Bespoke Manual Handling Programmes for their Poole Bakery and Dorset Foods sites. Pork Farms Market Drayton specifically produces sausage rolls and pies.

As part of our coverage of 88 Councils nationally (as off January 2020 when this Case Study was written), our provision for Dacorum Borough Council started in 2012 where we provided Instructor Programmes for their Waste Services and Grounds Teams. Following this in 2019 we provided a Manual Handling Risk Assessment for their Refuse, Recycling and Street Cleansing tasks and in 2020 trained more Instructors and 180 of their workforce.

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Kimal is an innovative and trusted manufacturer and supplier of specialised procedure packs and vascular access devices to hospitals across the world. Their Bromgrove site is a manufacturing facility and their Worcester site is a logistics warehouse. We have trained 12 Manual Handling Instructors over 2 Courses in 2016 and 2018.

For the Food Production Industry and Council Services sections of our 'Off the Shelf' Manual Handling Training DVD, we started filming in January 2020 at our client Pork Farm´s Market Drayton Bakery site and Dacorum Borough Council´s Cupid Green Depot. Our Business Director Gareth Milner teamed up again with Lawrence Fowler (pictured to the right) of Up a Notch Productions. Gareth and Lawrence had previously worked successfully on Osteopathic Solutions Bespoke Manual Handling Training DVD for British Pepper & Spice that was produced in 2018. To view this Bespoke DVD for British Pepper & Spice scroll down to the bottom of this page.


9th January 2020. Day 1 of Filming at Pork Farms, Market Drayton. The day started with a full factory tour with the site SHE Assistant. The gallery below showcases the manual handling tasks, loads and environments that were filmed. Meticulous as ever, Gareth consulted his structure sheet throughout the day so that all tasks, loads and environments available in the factory were covered. Like all the sections of our DVD, all industries can consult each section to learn the key principles of BackSafe Manual Handling Practice. Whatever you are lifting, carrying, lowering, pushing, pulling and team handling, the principles are always the same. Tasks filmed were:

  • Lifting & carrying of shortening & butter from pallets

  • Lifting, carrying & lowering crates of pastry

  • Lifting & carrying finished product boxes from roller conveyer

  • Lowering finished product boxes to pallet

  • Lifting & carrying bags of starch from pallet

  • Pushing & pulling of pallet trucks/ palletized loads in the factory & warehouse

  • Pushing & pulling of bakery cages, food totes & trolleys

  • Single Person Pushing & Pulling of commercial bins

  • Team Pushing of commercial bins

  • Team Pushing & Pulling of commercial bins

  • Single Person & Team Handling of pastry containers

  • Single Person & Team Handling of pallets

Like in all Food Factories nationally this site had awkward manual handling tasks. The task shown in the photo (to the right) involved lifting a roll of pastry from the trolley rack. 10 rolls of pastry (on a metal pole) with 5 on each side can be stacked on this trolley with lifting heights ranging from just below knee height up to head height. Gareth lifted the roll of pastry at head height and questioned the safety of this task with the SHE Assistant who informed him lifting equipment had been purchased on one of the lines. 8 lines were in this factory room which would be an £80,000 spend. The pastry roll is then carried 1 metre and lowered onto the machine at waist height with the left arm holding the load away from the body for a short time. There is then a static forward bend of the body to allow the pastry to roll out automatically on the machine top.

Are you struggling to convince Directors to spend on equipment to reduce Manual Handling Accidents?

Our Manual Handling Risk & Ergonomic Assessment Consultancy with a Full Company/ Site Risk Reduction Report can help you.

For more information click this link.

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To view more clips from our Filming view our YouTube page by clicking this icon

Like with our Bespoke DVDs, Gareth (with the agreement of the SHE Assistant) involved employees in the filming. In the gallery above Gareth is performing a team pull and push of a pastry container. Shown in the photo in the gallery, Gareth briefs the employee on best practice including pushing technique, and the communication Gareth would use to coordinate the team pull and push. Shown in the 3rd image in the gallery, what do you notice about the body use and positioning of the employee? Email your thoughts to us at the bottom of this page and receive 50% off our DVD.

Up a Notch Productions´ Lawrence Fowler also got in the manual handling action. Shown in the gallery Gareth and Lawrence perform team lifting, carrying and lowering of a CHEP pallet. Single person handling of CHEP practice is the norm in factories however 2 person handling or use of a vacuum lifter is simply best manual handling practice.

After a long day of filming Gareth and Lawrence finished the day with a sausage roll and cup of tea. Much appreciated Pork Farms Market Drayton!

10th January 2020. Day 2 of Filming at Dacorum Borough Council. The day started with a cup of tea in the staff canteen to warm up for a day of outdoor filming, and a discussion with the Dacorum depot team in what loads we needed to maximise the day’s effectiveness. Filming started in the depot equipment storage building with squat lifting, carrying and lowering of a range of grounds maintenance bagged loads from pallets. After each task Gareth observed the camera footage making sure his practice, technique and body use was best practice. Throughout the day, Dacorum Borough Council´s depot staff were taking a good interest in our filming, asking us questions about what we producing. Staff were very helpful in arranging loads across the depot and also providing us with a bit of photography. They would soon be watching the finished Manual Handling Training DVD as their employer Dacorum Borough Council was receiving a free copy.

Luckily this January day was nice and sunny aiding us to get outside to film pushing and pulling of wheelie, commercial and paladin bins, team handling of a fridge, throwing of a refuse bag and lifting of a traffic cone.

Lawrence of Up a Notch Productions had some free manual handling training himself as through Gareth´s coaching, Lawrence applied excellent technique and practice when performing team handling of a commercial bin, and team lifting and lowering of a fridge. Tasks filmed included:

Refuse & Recycling

  • Pushing & pulling of Wheelie Bins

  • Pushing & pulling of commercial bins

  • Lowering & lifting of stacked Wheelie Bins

  • Throwing of Refuse Bags

Street Cleansing

  • Throwing of Refuse Bags

  • Pushing & pulling of Street Barrows

  • Team Handling of Fridge Freezers, Sofas

Grounds Maintenance, Park & Open Spaces

  • Pushing & pulling of Trailors

  • Team Handling of Mowers, Generators

  • Lifting, carrying & lowering of strimmers, fluid drums, sand bags etc.

View our DVD Explainer Video & more video clips from our filming on our YouTube Page by clicking this icon

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More content to follow shortly.

Osteopathic Solutions Ltd

T:  0845 299 3513

E:  handling@osteopathicsolutions.co.uk

Company Registration Number: 07743200

VAT Registration Number: 139 388572

CPD Certification Service Member Number: 12602

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