The risk of over-protection
When it comes to workplace safety, more protection isn’t always better. In fact, “over-protection” is becoming a common and costly issue across the Australian food industry. Businesses eager to do the right thing sometimes choose safety equipment that exceeds what’s necessary for the task, leading to wasted spend, reduced worker comfort, and even compliance risks. The key isn’t simply to buy the “highest spec”- it’s to buy the right spec.
The Problem with Over-Protection
Safety PPE, like gloves and hearing protection, are designed with specific hazards in mind. When a spec is mismatched to the task, it creates unintended risks:
Gloves: A higher cut rating or thicker glove might seem like the safe choice, but it can reduce dexterity, slow down production, and lead workers to remove gloves altogether - defeating the purpose.
Hearing protection: Earplugs or earmuffs with very high noise reduction can “over-isolate” workers, making it difficult to hear alarms, communicate, or remain aware of their environment - ironically increasing risk.
In both cases, over-specification doesn’t improve safety outcomes. Instead, it increases costs and can undermine compliance if workers reject the PPE.
The Cost Benefits of Getting it Right
Taking the time to review your PPE specifications can deliver significant savings - without compromising safety.
- Avoid unnecessary spend: A lower spec glove that’s perfectly fit for the task can be more affordable and longer-lasting, especially if workers only use what they need.
- Boost productivity: The right level of dexterity or comfort helps workers complete their tasks more efficiently. If staff are comfortable, confident they are protected, and yet unhampered by overly heavy or bulky protective wear, they will likely be more productive.
- Reduce injury claims: On the other hand, under-protection can be costly. A single hand injury or hearing damage claim can far outweigh the savings of buying a cheaper, unsuitable spec. Investing in the correct level of protection helps prevent workplace injuries, downtime, and compensation payouts.
A Smarter Approach to PPE in Food Processing
The food industry faces unique challenges - strict hygiene requirements, repetitive manual handling, and often noisy processing environments. That’s why a spec review is one of the most valuable steps a business can take. By matching PPE exactly to the risks of each role - whether it’s selecting the right cut-level glove for knife work, or choosing hearing protection that reduces noise without over-isolating - you strike the balance between cost control and genuine worker safety.
Further considerations:
Worker Comfort and Retention
PPE that’s too heavy, hot, or isolating doesn’t just impact productivity - it impacts morale. In a tight labour market, uncomfortable gear can contribute to higher turnover. Finding the right spec means workers are likelier to wear their PPE consistently and willingly.
Training and Compliance
The right PPE spec only works if staff understand when and how to use it. Over-protection can confuse staff about what’s necessary, while under-protection creates risks of non-compliance. Training becomes much easier when PPE matches the hazard clearly and logically.
Industry Standards and Audits
Food processors are subject to regular audits from regulators and customers. Using PPE that’s not appropriate to the hazard - whether too much or too little - can raise questions about risk assessment processes. Documenting why a certain spec was chosen is part of demonstrating due diligence.
