Cutting is part of everyday life in industry, logistics, and retail: opening cardboard boxes, cutting through plastic film and strapping, or cutting materials to size. Precisely because these tasks are often performed as a side activity, their risks are easily overlooked. In 2024, the German Social Accident Insurance (DGUV) recorded over 34,000 reportable workplace accidents involving knives, kitchen knives, and box cutters. That accounted for 56.4 percent of all reportable accidents involving non-power-driven hand tools.
A safe cutting workstation involves more than just the knife. The key is the interplay between a safe cutting tool, ergonomics, lighting, and acoustics. All four factors can be specifically addressed in the hazard assessment and, in some cases, measured.
Safety knives: Reducing Risk at the Source
The STOP principle specifies the order in which protective measures should be implemented. Hazards should be avoided whenever possible or eliminated through safer alternatives. Technical measures address the source of the hazard directly, before organizational and personal measures are implemented.
A manufacturer and supplier like MARTOR is effective on several levels: Suboptimal cutting tools can be replaced with professional Safety knives (substitution). Integrated Safety technology further reduces the risk of cutting accidents (technical measures). Training, education, and practical resources help to permanently embed safe cutting practices into everyday work routines (organizational measures).
The most suitable alternative or technical solution depends on the cutting material, the cutting depth, the frequency of cuts, and the workflow. MARTOR offers a variety of cutting tools and Safety technologies for this purpose. However, the result is always the same: potential blade contact is minimized—for example, through a concealed blade or an automatic or fully automatic blade retraction mechanism.
It is not possible to quantify, using a reliable, universally applicable percentage, the extent to which Safety knives reduce cuts overall. Applications and workplace conditions vary too widely for that. What can be measured, however, is the baseline risk—and thus the need to include safe work equipment in the risk assessment. Real-world case studies show, however, that companies have succeeded in reducing the number of cutting accidents to zero within a few years.
Ergonomics: Avoiding Strain
An ergonomic safety knife is particularly gentle on the hand and arm, even during frequent cutting. But more is needed to ensure a comfortable, effort-saving work process. Work height, reach distances, material flow, and the arrangement of work equipment must therefore be examined more closely. For example, height-adjustable work surfaces and short reach distances are ergonomically sound. Also worth mentioning here is a non-slip mat to secure the material being cut.
Recent data from the 2024 BIBB/BAuA Workforce Survey highlight the significance of this issue: Among employees who frequently perform manual tasks—such as those requiring significant strength, high dexterity, or rapid repetition—45 percent reported three or more musculoskeletal complaints. Among employees who were exposed to such demands only sometimes or never, the figure was 22 percent. For those who frequently worked while standing, the proportion was 40 percent compared to 19 percent.
This is not evidence of a blanket “ergonomic effect” of x percent. However, it does show how closely physical strain and discomfort are linked.
Light: See where you're cutting
Adequate lighting is another requirement for controlled cutting. The blade, the cutting line, the material, and your free hand must be clearly visible.
The Technical Rule for Workplaces (ASR A3.4) specifies a minimum of 300 lux and a color rendering index (Ra) of at least 60 for shipping and packaging areas. In the case of area-specific lighting, the average illuminance at the workstation must be at least 500 lux; it must not fall below 300 lux at any point.
Glare, reflections, and extreme differences in brightness can also make it harder to see and make a cutting workstation less safe.
Acoustics: Maintaining Concentration
Noise can impair concentration, attention, and speech intelligibility—and thus affect activities that require precise hand movements. Over time, noise can also cause health problems.
ASR A3.7 distinguishes between different categories of work. For tasks requiring sustained high concentration, a maximum assessment level of 55 dB(A) applies; for tasks requiring moderate or non-sustained concentration, the level is 70 dB(A). For tasks with lower concentration requirements, a minimization requirement applies. The category applicable to a cutting workstation must be determined based on the specific task.
This should be distinguished from the guidelines for hearing protection. The STOP principle applies here as well. It is best to avoid noise or reduce it to a minimum. If that is not possible, the Occupational Safety and Health Regulation on Noise and Vibration stipulates that suitable hearing protection must be provided at noise levels of 80 dB(A) or higher. At or above 85 dB(A), the employer must ensure that such protection is actually used.
Workplace Safety as a Comprehensive System
A safe cutting workstation is not achieved through a single purchase or measure. Ergonomic safety knives can significantly reduce the risk of accidents and allow users to work with less strain. The consistently ergonomic design of the entire cutting workstation, including the tool, protects the user from long-term poor posture. In addition, training and work organization play a key role: How do I use a cutting tool as safely and efficiently as possible? What reliable routines are recommended for storing the cutting tool, for blade change, disposal, and cleaning? Here, too, MARTOR provides practical guidance.
Lighting and acoustics provide the framework for a safe and healthy work environment: Adequate, glare-free lighting ensures better visibility. Proper acoustics promote concentration and communication and reduce stress.
It is essential to bring all factors together in the risk assessment, to regularly review its effectiveness, and to make adjustments to the workplace as needed.
This turns “safe cutting” into a verifiable workplace concept—with measurable criteria for occupational health and safety.
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