Ergonomic Auxiliary Handles for Hand Tools (Optimized): Improving Health and Productivity for Under-resourced Farmers

Commodities

Practices

Project Title: Ergonomic auxiliary handles for farming tools: improving health and productivity for under-resourced farmers

This project aims to develop, test, optimize, and disseminate ergonomic auxiliary handles for long-handled farming tools, specifically shovels and pitchforks, used by under-resourced farmers and ranchers. These handles will be designed to reduce musculoskeletal strain, improve tool control, and increase task efficiency, particularly for women farmers under high physical stress. The solution addresses gaps in existing tool designs by tailoring handle configurations to diverse anthropometrics and ergonomic safety guidelines.

This project builds on research from a previous SARE-funded study, "Ergonomic Effects of Auxiliary Handles of Hand Farming Tools on Women," which evaluated two commercially available handles: EAHA (RAH! Handle by Flipo Group) and EAHB (BackEZ Ergonomic Handle by Schaper's), used with and without a conventional tool. Findings showed significantly reduced hip flexion and moderate reduction in energy expenditure, However, increased elbow and shoulder strain was observed in participants, prompting this study's inclusion of more adjustable and rotational handle features to mitigate such trade-offs.

Two advanced ergonomic handle prototypes (ErgoFlex-1/ErgoCore-1 and ErgoFlex-2/ErgoCore-2) have been designed but not yet tested. Prototype 1 allows ±45° rotation, while Prototype 2 offers full 360° rotation (±180°). Each supports handle angles of 16°, 32°, and 48°, with adjustable extension lengths (0 mm, 20 mm, 40 mm) in ErgoFlex and fixed lengths in ErgoCore.

Six additional prototypes will be developed, totaling eight, and systematically tested in 26 ergonomic configurations. Forty female farmers will perform simulated shoveling and pitchforking tasks. Postural data will be analyzed using AI-powered ergonomics software and RULA/REBA frameworks. Cardiovascular strain and energy expenditure will also be measured, supplemented by subjective feedback on usability and comfort.

Findings will identify optimal handle geometries that significantly reduce ergonomic risk and physiological strain. Outreach efforts include the development of extension publications, farmer-led demonstrations, and conference presentations, including a farmer-focused educational package. These materials will demonstrate proper ergonomic techniques, handle adjustment tips, and positioning guidelines, including the optimal 13 to 17-inch placement from the handle top, based on user height and task type. Special emphasis will be placed on ensuring usability by older farmers, small-scale operators, and ranchers engaged in repetitive manual tasks like mucking, forking hay, or clearing pens.

This project directly supports NCR-SARE's goals of improving farm viability, preserving physical health, and reducing reliance on costly mechanization, ultimately lowering injury rates, improving work quality, and fostering equity in agricultural tool design.

This project will produce both learning and action outcomes for under-resourced farmers, particularly women, older adults, and smallholder producers. Through field demonstrations, illustrated booklets, educational videos, and a project website, farmers and ranchers will gain knowledge about the optimal positioning (13-17 inches from the blade) and angular adjustments (16°, 32°, 48°) of auxiliary handles that match diverse anthropometric profiles. They will learn to identify postures and tool adjustments that reduce musculoskeletal strain during digging, lifting, and mucking tasks.

We expect at least 95 farmers and ranchers to attend workshops, with at least 40 participants reporting an increased knowledge of safe ergonomic tool use and improved awareness of MSD risks. Farmers will also learn how to evaluate tool handle placement based on body size and task demands.

Action outcomes include increased adoption of ergonomically modified long-handled tools and safe work techniques among participants. At least 30% of engaged farmers report making a change in their tool use practices either through handle adjustments, purchasing ergonomic add-ons, or modifying work routines to reduce back, shoulder, or wrist strain. Adoption will be tracked through pre- and post-training surveys, user testimonials, follow-up interviews, and online engagement metrics (including video views, tool downloads).

In the long term, these outcomes contribute to improved economic viability through reduced injury downtime, environmental sustainability by supporting manual precision over fuel-powered alternatives, and quality of life by increasing safety, comfort, and confidence among traditionally underserved producers.