COLD STORAGE AND FOOD PROCESSING

The cold storage and food processing industry plays a vital role in the global food supply chain by preserving perishable goods using refrigeration systems for quality and safety. This sector employs essential mobile machinery such as forklifts, pallet jacks, and conveyor belts for efficient sorting and packaging operations. However, these machines pose safety risks such as collisions, limited visibility, and ergonomic strain. Incident Zero’s Safety Halo system reduces these risks with visible exclusion zones based on human instinct. This enhances safety and operational efficiency in critical facilities.

Machinery and associated risks

In cold storage and food processing facilities, several types of mobile machinery are essential for various operations:

• Forklifts: Used for transporting pallets of goods within warehouses and loading/unloading trucks.

• Pallet jacks: Also known as pallet trucks or pump trucks, used for lifting and moving pallets over short distances.

• Order pickers: Vehicles equipped with platforms for operators to pick items from high shelves in warehouses.

• Electric tuggers: Used for towing heavier loads or multiple carts within the facility.

• Reach trucks: Reach trucks are similar to forklifts but, they are designed for accessing high racks in narrow aisles.

• Conveyor belts: Mobile conveyor systems for efficiently moving goods between processing stages.

• Automated guided vehicles (AGVs): Self-guided vehicles that transport goods automatically along predefined paths.

These mobile machines are integral to the smooth operation of cold storage and food processing facilities, ensuring efficient logistics and timely processing of perishable goods while adhering to stringent hygiene and safety standards.

In cold storage and food processing facilities, several safety concerns are associated with the mobile machinery used:

• Collision risks: Due to the confined spaces and busy environment, collisions between mobile machinery and pedestrians or stationary objects are common.

• Visibility issues: Limited visibility for operators, especially in areas with stacked goods or narrow aisles, increases the risk of collisions or accidents.

• Slippery surfaces: Cold storage environments often have slippery floors due to condensation or ice formation, posing a hazard for mobile machinery.

• Ergonomic strain: Operators may face ergonomic risks from repetitive motions or awkward postures while operating mobile machinery, making the operator distracted and reducing focus on their surroundings.

• Training and competency: Adequate training for operators is crucial to ensure they understand the specific hazards and operational procedures in these environments.

Incident Zero’s Safety Halo™ system effectively mitigates the risk of mobile plant in cold storage and food processing environments by leveraging the intrinsic human response to danger. By creating visible exclusion zones around operating machinery using lasers or LED lights, the Safety Halo prompts an immediate and instinctive reaction in individuals to avoid these marked areas. This proactive approach ensures that humans are kept out of danger zones altogether, thereby eliminating the risk of accidents and collisions posed by mobile plant machinery. The system’s ability to induce safe behaviours by enhancing awareness and guiding personnel away from hazardous areas contributes significantly to maintaining a safer working environment in these facilities.

Paint and line marking

Paint and traditional line marking are not ideal solutions in cold storage and food processing facilities due to several reasons:

• Durability issues: The cold and damp conditions in these facilities can cause paint to deteriorate quickly. Moisture, temperature changes, and cleaning with harsh chemicals can lead to fading, peeling, or complete loss of the markings over time.

• Hygiene concerns: Paint can harbor bacteria and contaminants if not properly maintained or if it chips or flakes off. This poses a risk of contamination to food products, which must adhere to strict hygiene and safety standards.

• Maintenance Challenges: Regular maintenance of painted lines is labour-intensive and disruptive to operations. Reapplying paint or touching up markings requires downtime and may necessitate moving equipment or products, impacting productivity.

• Visibility and clarity: Painted lines may become less visible over time due to wear or environmental conditions. In cold storage environments, condensation or frost buildup can obscure painted markings, making them less effective for guiding traffic or delineating work zones.

• Regulatory compliance: Food processing facilities must adhere to stringent regulations regarding hygiene and safety. Painted markings may not meet these standards if they degrade or pose a contamination risk.

Laser line marking from Incident Zero offers several advantages over traditional paint in cold storage and food processing facilities:

• Durability: Laser line marking systems create permanent markings that are resistant to moisture, temperature fluctuations, and cleaning chemicals. They do not fade, peel, or degrade over time, ensuring long-lasting visibility and reliability.

• Hygiene and safety: Unlike paint, laser markings do not chip or flake, eliminating the risk of harbouring bacteria or contaminants. This maintains strict hygiene standards crucial for food safety in processing facilities.

• Ease of maintenance: Once installed, laser markings require minimal maintenance. They do not need regular touch-ups or reapplications, reducing downtime and operational disruptions.

• Visibility and Ccarity: Laser lines are precise, clear, and highly visible, even in cold and low-light conditions. They provide consistent markings that are easy to see and follow, enhancing safety and efficiency in navigating the facility.

• Compliance: Laser line marking meets regulatory standards for cleanliness and safety in food processing environments. It ensures compliance with hygiene regulations without compromising operational efficiency.

Overall, Incident Zero’s laser line marking systems offer a reliable and hygienic solution for cold storage and food processing facilities, addressing the shortcomings of traditional paint while enhancing safety, efficiency, and regulatory compliance in these critical environments.