Ergonomic Risk Assessment in Manual Handling of Loads During Cocoa Drying and Winnowing Processes

Abstract

The cocoa industry is a fundamental component of the agro-industrial sector, where manual handling of loads (MHL) remains a predominant activity in drying and winnowing processes. These operations pose significant challenges to occupational safety and health due to high physical demands and the presence of disergonomic risks that contribute to musculoskeletal disorders and reduced productivity. In this context, applied ergonomics becomes essential for ensuring safe and sustainable working conditions. This study evaluated disergonomic risks in a cocoa collection and processing facility through standardized methodologies, including the NIOSH Lifting Equation, REBA, and OWAS. Specific tasks such as lifting sacks (40–60 kg), grain turning, and tray transport were analyzed. The obtained Lifting Index values (LI 2.8–3.5) exceeded recommended limits, while REBA scores (8–11) and OWAS postures (categories 3–4) indicated high-risk levels requiring immediate intervention. The combination of excessive loads, awkward postures, and task repetitiveness created a biomechanically hazardous environment for workers. At the operational level, recurrent lower-back overload, fatigue in shoulders and wrists, and difficulties in safely handling loads were identified, largely due to the absence of mechanical aids and inadequate working heights. These factors increase the likelihood of injuries and directly affect the efficiency of daily activities. The findings highlight the urgent need for ergonomic improvements in processes, continuous worker training, and workstation redesign to mitigate disergonomic risks and protect worker health.