LTB 249/25 - Royal Mail ‘Correx’ (Plastic) York Container Sleeves – Update to Branches
- Angela Wright CWU Branch Communications Officer
- Nov 17
- 4 min read
No. 249/25
Dear Colleagues,
Royal Mail ‘Correx’ (Plastic) York Container Sleeves – Update to Branches
Branches, Representatives and members will recall previous LTBs issued in terms of the decision by Royal Mail to introduce the ‘Correx’ Sleeves into the automated and manual sorting operations from late 2022 and its decision to remove ‘Red’ Auto-Level Packet (ALP) Sleeves completely from the operation in October 2023, the last being LTB 220/24.
As reported, this decision by Royal Mail to move forward with both the ‘White’ and ‘Green’ Correx Sleeves in the manual operation was taken without any proper trials, proof of concept or meaningful consultation with the Union and was against the strong health, safety and ergonomic objections from the former CWU Health, Safety and Environment Department.
The purpose of this LTB is to update Branches on development since then and to date:
HSE Complaint and Investigation Request
As reported in LTB 220/24, arrangements were established for the HSE (Health & Safety Executive) to visit the Heswall Delivery unit in Wirral, in June 2024, to fully investigate the CWU’s documented concerns regarding the use of Correx Sleeves in the manual operation. Disappointingly, and without any explanation, the HSE visit did not take place.
Independent Commissioned ‘Ergonomic and Safety’ Review
As previously reported, Royal Mail finally agreed to an independent commissioned ‘ergonomic and safety’ review of the use of the Correx Sleeves both in terms of short-term injury risks and the long-term cumulative effects of the use of Correx Sleeves in the manual operation.
Although Royal Mail confirmed in June 2024 that this ergonomic study would be undertaken by David Annett, Osteopath and Ergonomics consultant of the ‘Ergotherapy’ Company, it was not until April this year however that the report was finally shared with the CWU.
Following receipt of the two Ergonomic Reports commissioned by Royal Mail, further talks were held with Royal Mail via the National Safety Committee. This resulted in both parties agreeing to set up a limited Joint Working Group to hold discussions around Correx Sleeves with the starting point for the JWG being the two Ergonomics Reports and some outlined ‘design changes’ of the Correx Sleeve. This JWG was established on a without prejudice basis for both parties but equally based on seeking a fresh approach to Correx Sleeves.
The JWG started meeting in August and as a result of this, the following design and operational changes are now in place:
Royal Mail have now moved over to a new material for Correx Sleeves based on a plasticiser additive, which will make the material softer and less abrasive. This change in the Correx Sleeve material is already in place with the supplier, who has advised that they can move forward with this change at pace.
This change should have the benefit of providing increased material flexibility and reducing the current fragmentation, alongside being less brittle than the current material, which aims to reduce subsequent abrasion/cut risks currently reported in the operation. These Correx Sleeves, based on the new material, should already be filtering into the network and will be noticeable due to their darker colour compared to the current ‘White’ version.
Additionally, newly produced Correx Sleeves will be reduced in height to diminish the risk of arm abrasion when using the York, in particular, when nesting Yorks. This will be alongside a ‘cut out’ or ‘visibility window’ at the top of the rear of the Sleeve to give greater forward visibility when moving Yorks.
Decals (labelling) added to Yorks where trays cannot be used within them.
Decals (labelling) added to sleeves to remind users of the need to put the door back fully upright before nesting the York.
The move over to black coloured ‘rivets’ in Correx Sleeves to offer greater floor visibility to achieve better clearing up where they become damaged and fall off, seeking to reduce a slip hazard.
The removal of the ‘Snow’ shovel, which was initially introduced by Royal Mail to support the manual sorting operations and the retrieval of smaller parcels and items at the bottom of Correx Sleeves.
The introduction of a ‘Green’ Auto-Level Packet (ALP) Sleeve for SD Locker mails with each Mail Centre initially being issued 200 of these Sleeves for operational use.
In addition to these design changes, a revised SSoW (Safe System of Work) has been issued by Royal Mail covering the use of Yorks and Mini-Yorks in the operation, which sets out an enhanced focus on the importance of task variation and relief to ensure a change in posture when sorting/unloading parcels from the Correx Sleeve, alongside confirming a maximum sorting/unloading duration.
Attached is a copy of the revised Operation and Use of Yorks and Mini-Yorks SSoW, Version 3.5, which confirms:
When unloading parcels, follow one of these task variation methods to ensure a change in posture:
Method 1) Task rotation every hour – switch to a distinctly different task that allows you to stand upright and doesn’t involve bending OR
Method 2) Stretch and take a short relief from bending:
After each York for at least one minute OR
After every third York for at least three minutes
Unloading Yorks MUST NOT exceed 4 hours in an 8-hour shift. By exception if more than 4 hours is approved, follow the local approved additional controls.
Also attached is a copy of a Royal Mail WTLL briefing issued on the 10th November, reporting on the changes to the SSoW on the use of Yorks and Mini-Yorks.
These outlined changes although limited, are viewed as positive and need to be set against the position that Correx Sleeves have been embedded in Royal Mail for over two years with little to no change in their original design and use since deployment.
It is equally important to confirm however that our discussions via this JWG remain ongoing and we equally continue to press Royal Mail on the union’s remaining and wider concerns linked to Correx Sleeves and ergonomic risks in the manual operation, which, given the background to date, remain fundamentally challenging.
Further updates will be issued in due course.
Any enquiries in relation to the content of this LTB should be addressed to the DGS(P) Department hford@cwu.org
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Yours sincerely,
Martin Walsh
Deputy General Secretary (Postal)
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