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Workplace Transport and Pedestrian Safety:
Enhancing Health and Safety in Paper Mills
ZoneSafe’s proactive proximity detection enhances health and safety in paper mills by protecting at the people-plant interface.
What are the critical dangers to health and safety in paper mills?
In paper mills, critical dangers to health and safety stem from unintended transport hazards, particularly where pedestrians and vehicles interact, significantly increasing the risk of fatal and severe injuries from accidents. This danger is often exacerbated by limited visibility in environments where the movement of large loads and machinery can severely obstruct views and clear lines of sight.
According to RIDDOR data:
- The manufacturing sector experienced 16 fatal injuries to workers in 2023/24, with a five-year average of 17 deaths per year.
- Being struck by a moving vehicle caused 25 worker fatalities across all industries in 2023/24, representing 18% of all worker deaths.
The persistent and serious nature of transport-related risks highlights the critical need for robust safety measures in manufacturing, including operations like paper mills. This is vital for protecting workers, and indeed, under health and safety law, employers have a legal duty to ensure, as far as reasonably practicable, their employees’ health, safety, and welfare.
Our pedestrian detection system actively boosts situational awareness and promotes safer practices within paper manufacturing facilities, effectively lowering the chance of collisions between vehicles and pedestrians, thereby improving health and safety in paper mills..
We’re proud to protect workers and health and safety in paper mills, delivering a tried-and-tested proximity warning system that promotes a ‘Zero-harm’ culture. Find out exactly what our customers say about ZoneSafe in our case study videos.
*These provisional figures will be finalised in July 2025. This allows HSE to account for any necessary adjustments or late reports that may come in.
Sector Statistics up to 2023/2024*
%
Non Fatal Injuries to Workers Struck by Moving Vehicles
x
Higher Fatality Rate Than Average Across Industries
Fatal Injuries to Workers Per Year
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How does ZoneSafe enhance health and safety in paper mills?
ZoneSafe enhances health and safety in paper mills by providing advanced proximity warning technology that eliminates vehicle blind spots and detects pedestrians without relying on line of sight, ensuring comprehensive protection and immediate alerts to prevent collisions.
Keeping your workforce safe on busy worksites operating heavy plant machinery is no easy task. Vehicle blind spots, concealed entrances, blind corners, obstructions and unexpected behaviours all increase the risk of a pedestrian being hit by a moving vehicle.
Unlike other solutions available on the market, such as an AI camera system, Zonesafe’s pedestrian detection system does not rely on line of sight, and it will detect pedestrian workers (even when they can’t be seen!) from behind walls, racking, pallets and even paper reels, thanks to its clever use of RFID technology.
ZoneSafe’s pedestrian detection system works by fitting an antenna to the vehicle. This creates a 360-degree detection zone around the vehicle, helping to eliminate vehicle blind spots. Pedestrian workers wear a ZoneSafe tag, which the antenna detects every time the pedestrian (and tag) enters the detection zone. Once detected, the in-cab control unit warns the driver via an audible and visual alarm, and the tag worn by the pedestrian vibrates, alerting the pedestrian to the danger of the approaching vehicle.
Multi-fleet vehicle applications:
Protecting pedestrians around paper mill machinery
Safeguarding health and safety in paper mills is achieved through multi-fleet vehicle applications that prioritise pedestrian protection around essential paper mill machinery.
Shovel Loaders
Shovel loaders are a significant hazard to pedestrians. Large buckets, attachments, even the shape of the vehicle creates blindspots for the driver and increases the risk of collisions.
Forklifts
Forklifts have many different blind spots thanks to the loads they carry, distorted view from the cab and shape of the vehicle. These significantly increase the risk of collisions.
Can ZoneSafe systems adapt to diverse paper mill environments?
ZoneSafe systems are specifically designed for high adaptability, ensuring effective health and safety in paper mills across diverse layouts and operational areas.
While segregating moving vehicles and pedestrian workers is essential, it’s often not possible in many areas within paper mills.
ZoneSafe bridges this safety gap by working effectively in environments where vehicle-pedestrian interaction is frequent and segregation is challenging, including:
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Pulping
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Sheet formation
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Environmental/effluent treatment
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Woodyard/fibre procurement
Activated Signage
Implementing ZoneSafe's vehicle-activated signage provides a practical solution to enhance onsite safety. Signs only flash when the vehicle is present, warning both site users and visitors located in the area to any approaching vehicles.
Site Access Control
Restricting site access to only your employees or anyone given a ZoneSafe tag reduces the risk of accidents. Only ZoneSafe tags open gates or barriers to a restricted area meaning they'll be detected and warned should they get too close to a moving vehicle.
Vehicle-to-Vehicle Detection
Reduce the risk of accidents between moving vehicles with ZoneSafe vehicle detection anti-collision system. Fitting any type of vehicle, the system provides two configurable warning zones, an outer pre-warning (or early warning) zone and inner (close proximity) warning zone.
Data Management
My.ZoneSafe, is our cloud-based insight and data management platform, which records and displays event data (such as near miss occurrences) to inform Health and Safety managers of potential hazards and collision hotspots.
What are the benefits of using proximity warning systems for health and safety in paper mills?
Implementing ZoneSafe proximity warning systems brings significant benefits to health and safety in paper mills, leading to fewer accidents, improved compliance, and enhanced operational efficiency.
✔ Fewer workplace accidents lead to savings on medical expenses, compensation claims, and repairs to expensive equipment.
✔ Helps paper mills meet stringent health and safety regulations, avoiding potential fines and improving compliance.
✔ Reduces downtime caused by accidents and disruptions, ensuring smoother operations in high-traffic areas.
✔ Proximity warning systems prevent collisions between forklifts and workers in busy paper mills, reducing the risk of injury.
How has ZoneSafe improved health and safety in paper mills for other organisations?
Hear from our customers: paper mill safety case studies
Mondi is a leading manufacturer in packaging and paper, employing around 26,000 people across more than 30 countries.
“Since implementing ZoneSafe’s proximity warning systems, our workplace safety has significantly improved. After experiencing a near-miss with forklifts and pedestrians, we knew we had to take immediate action. We’re proud to say that since adopting ZoneSafe, we’ve had no incidents or near-misses, and we’ve now extended this technology to multiple sites across Europe.”
Other Projects We’ve Delivered
Virginia Hayward,
Warehousing & Logistics
Warehousing & Logistics
Virginia Hayward has reported a dramatic reduction in the number of near misses and accidents since the implementation of ZoneSafe.
Gray Forklift Services,
Forklift Truck Supplier
Forklift Truck Supplier
Gray Forklift Services Ltd selected ZoneSafe to manage their fleet of trucks and health and safety needs.
SAAM Ports,
Cargo Support Services
Cargo Support Services
SAAM carried out an evaluation project to find a solution to protect personnel and assets from vehicle collisions within their ports.
Liberty Steel,
Steel Manufacturer
Steel Manufacturer
Liberty Steel implemented a safety and asset protection system designed to stop cranes from colliding.
See how ZoneSafe can provide a solution for you Get in touch