Almost 1 in 3 workplace injuries to young Australian workers are cuts from knives and cutting tools, according to WorkSafe Queensland. ¹ Yet most of these injuries are entirely preventable with proper knife safety training.

Despite this, many WHS programs overlook cutting tool safety—assuming that because the task is routine, workers inherently know how to perform it safely. This assumption costs Australian businesses thousands in compensation claims and lost productivity each year.

Warehousing, logistics, manufacturing, and retail operations depend on cutting tools for opening packaging, breaking down boxes, and removing shrink wrap—tasks performed thousands of times daily across Australian facilities. Here at MARTOR Australia, we've witnessed firsthand how proper knife safety training can reduce cutting injuries by up to 70% in facilities that implement structured training programs.

This is why knife safety training should be a core component of every WHS program, not an afterthought. It's also why MARTOR strongly advocates for safety audits, refresher training, and regular 'Toolbox Talks'—brief 10–15-minute safety discussions held weekly or bi-weekly that reinforce your company's safety protocols without disrupting operations.

Download our free Toolbox Talk guide or continue reading to learn how to structure knife safety education into your Workplace Health and Safety program.

Workplace Cutting Injuries: More Common Than Most Managers Realise

The most common workplace lacerations typically occur while workers perform everyday tasks, such as:

  • Incorrectly opening cartons

  • Cutting material with an incorrect choice of blade

  • Applying too much force

  • Cutting towards the body

  • Employing dull or damaged blades

As many of these tasks feel routine (and indeed, they often are), it's not difficult for workers to succumb to complacency. Lacking formal training and regular refresher courses, workers often develop and reinforce unsafe habits that grow more dangerous over time. This danger can be neutralised with a WHS program that recognises routine tasks demand structured safety controls.

Toolbox Talks Reinforce Safe Cutting Habits

At MARTOR, we believe that Toolbox Talks are one of the most efficient ways to teach correct knife safety practice.

A Toolbox Talk is:

  • Short and to the point (no pun intended)

  • Practical and educational

  • Easy for any workplace to adopt and implement

  • An extremely effective way to promote a change in dangerous behavioural patterns

A Toolbox Talk can cover:

  • How to cut in the correct direction

  • How to correctly position your body and grip the blade

  • How to know when it's time to replace a blade

  • How to safely replace a blade

  • The correct way to store knives safely

Toolbox Talks are designed to be short and focused—typically 10-15 minutes—so they can be inserted into a busy production schedule to reinforce key safety protocols without drastically disrupting the day's operations. With that said, it's important to acknowledge that one Toolbox Talk isn't enough. If you wish to enforce workplace safety, then regular reinforcement is needed, and consistency is key.

Safety Audits Identify Hidden Risks

Knife safety training works best when coupled with workplace safety audits.

A safety audit helps you assess the following:

  • Are the correct knives being used for the job at hand?

  • Are workers using incorrect tools and/or are they using the correct tools but in improper ways?

  • Are the blades being replaced when needed, and replaced in a safe manner?

  • Are old blades being disposed of in designated sharps containers—never in general waste where they can injure cleaners or waste handlers?

  • Are there clear and safe knife storage procedures?

Safety audits typically reveal issues that can lead to serious injuries if left unchecked. By implementing routine knife checks into your larger WHS audits, you ensure that proper workplace safety is taught, learnt, and implemented.

Refresher Training Prevents Complacency

Even the most seasoned workers can still benefit from refresher training on an annual or biannual basis, especially as it's all too easy for dangerous habits to become more prevalent over time.

New employees often learn by watching their more experienced colleagues, which sometimes means they adopt unsafe habits that are prevalent in the workplace. To combat these issues, it's essential to hold annual or biannual refresher sessions:

  • Sessions re-establish best practices and ensure everyone adheres to established safety protocols

  • They provide an opportunity to update teams on any new safety tools or technologies

  • Sessions reinforce the importance of accountability among all employees, creating a culture of safety

  • These efforts reduce trends related to workplace injuries, fostering a safer environment for everyone

It's important to note that knife safety is not a one-time training event; rather, it should continually evolve in tandem with your workforce and operational changes.

How Knife Safety Training Protects Your Business and Reduces Costs

In addition to minimising injuries, knife safety training offers significant advantages for businesses:

  • Decreased lost-time injuries

  • Lower workers' compensation claims

  • Less operational downtime

  • Enhanced compliance with WHS regulations

  • A more robust safety culture

When employees are confident in using the appropriate tools correctly, productivity increases and risks reduce.

How to Integrate Knife Safety Into Your WHS Program

You can successfully commence your knife safety integration by adopting this simple framework:

  • Organise a toolbox talk on knife safety

  • Perform an audit of basic cutting tools

  • Standardise the use of approved safety knives

  • Establish procedures for blade disposal

  • Plan annual refresher training

Even small, consistent enhancements can lead to significant improvements.

Implementing Knife Safety Training: Next Steps for Your WHS Program

Workplace cutting injuries can be prevented, but not without actionable steps built around structure, awareness, and reinforcement. If knife usage is integral to your daily operations, then incorporating knife safety training into your WHS program is nothing short of essential.

MARTOR Australia offers top-of-the-line safety knives, safe-cutting guides, training materials, and ready-to-use Toolbox Talk resources to aid in injury reduction and enhance compliance.

Download Your Knife Safety Toolbox Talk

To assist you in getting started, we've developed a free, ready-to-use Toolbox Talk resource for your team. 

Download the Safety Toolbox Talk today and take a significant step towards a safer workplace. Toolbox Talk download.

If you have any questions or need help getting started, contact MARTOR Australia for consultation and resources.

 

Workplace Knife Safety: Common Questions Answered

What is a Toolbox Talk and how long does it take?

A Toolbox Talk is a brief 10-15 minute safety discussion held with workers before or during a shift. It focuses on a single safety topic—in this case, knife safety—and reinforces proper procedures through short, practical reminders.

What topics should be included in a Knife Safety Toolbox Talk?

A Toolbox Talk on knife safety should emphasise practical, everyday cutting habits, such as the proper cutting direction, how to grip the tool, when to change the blades, how to dispose of blades safely in designated sharps containers, and the importance of personal protective equipment (PPE).

Why are Toolbox Talks crucial for knife safety training?

Toolbox Talks reinforce safe behaviours, keep knife safety at the forefront, and serve as ongoing reminders that even routine tasks carry risks, helping to prevent complacency before accidents happen.

How frequently should knife safety training be implemented?

Knife safety training should not be a one-and-done event. Regular refresher sessions should be held at least annually or biannually to reinforce safe practices and inform teams of any new procedures or tools.

What distinguishes a safety knife from a traditional cutter?

Safety knives are equipped with protective features like concealed blades (where the blade never contacts skin or products), retractable blades, or auto-retracting mechanisms. Advanced models like the SECUMAX 370 provide up to 10mm cutting depth while keeping the blade fully concealed throughout the cut. In contrast, traditional cutters typically have fixed, exposed blades, which heighten the risk of injury.

Do I need to provide knife safety training if we use safety knives?

Yes. Even the safest knife designs require proper training. Workers need to understand correct cutting techniques, how to adjust blade depth (for models like the SECUMAX 370), when to replace blades, and safe storage procedures. Safety knives reduce risk, but training eliminates preventable injuries.

Why is conducting a safety audit important for knife usage?

A safety audit identifies whether the appropriate knives are in use, if blades are replaced correctly, whether unsafe tools are being utilised, and if procedures are being followed, transitioning knife safety from mere policy to actual practice.

What should be done if a worker persists in unsafe cutting habits?

Regular Toolbox Talks and refresher training help identify unsafe behaviours. Address these through coaching, corrective actions, and reinforcing WHS expectations. If necessary, update procedures to make compliance easier and more intuitive.

References

1. WorkSafe Queensland. 'Knives at work.' Workplace Health and Safety Queensland, https://www.worksafe.qld.gov.au/safety-and-prevention/hazards/workplace-hazards/dangers-in-your-workplace/knives-at-work. Accessed 25 March 2026.

2. WorkSafe Queensland. 'Safe use of knives at work.' eSafe Newsletter, October 2021, https://www.worksafe.qld.gov.au/news-and-events/newsletters/esafe-newsletters/esafe-editions/esafe/october-2021/safe-use-of-knives-at-work. Accessed 25 March 2026.

3. WorkSafe Queensland. 'Young workers.' Workplace Health and Safety Queensland, https://www.worksafe.qld.gov.au/?a=9666. Accessed 25 March 2026.