When it comes to forklift safety, good operator training will always be Number One. But a variety of lift truck accessories, devices, and technology products can also help you enhance safety for forklift operators and pedestrians in your warehouse. Here are some recent examples that are now on the market.
FORKLIFT ANTI-COLLISION SYSTEM
ELOshield, a forklift anti-collision system, made its U.S. debut at the Modex 2018 show in Atlanta. ELOshield was developed by Elokon, a European provider of lift truck safety technology.
ELOshield is a UHF (ultra-high-frequency)-based warning system that helps prevent industrial truck accidents (both vehicle-to-vehicle and vehicle-to-person). A fixed-site version monitors accident-prone areas, such as high-traffic aisle intersections. A mobile version monitors zones of up to 50 feet around moving vehicles. These zones can be programmed, by vehicle, as circles, symmetrical rectangles, or asymmetrical polygons. Two zones, representing "warning" and "danger" risks, can trigger different system reactions.
When trucks get too close to each other or pedestrians, the truck-mounted display sends an audible and/or visual alert, automatically slows the truck down to "creep speed," and, if desired, stops the truck. If pedestrians come too close to a truck, their tags vibrate and sound an alarm.
This advanced driver-assistance system includes ID tags for industrial trucks, pedestrians, and fixed locations (like racking or doorways), as well as operator displays for each vehicle and a charging system for the pedestrian tags. (Elokon, www.elokon.com)
FORKLIFT SAFETY STROBE LIGHTS
TVH in the Americas (TVH), a supplier of replacement parts for material handling and industrial equipment, has added new dual-color strobes to its ML2 LED, ML5 LED, and ML55 LED series forklift safety lights. These strobes come in four different color combinations: amber/blue, amber/clear, amber/red, and blue/red. The dual-color option is ideal for alerting other workers of a forklift's action, the company says. If the forklift is moving, the strobe will flash one color. When the forklift is stopped and the forks are lifting, the strobe will flash the other color, indicating that the forklift is in use and not just parked.
Each strobe series is rated 12-80VDC. All of the units have six LEDs per head (three of each color) and come with a two-year warranty. (TVH in the Americas, www.tvh.com)
STANDUP FORKLIFT UNDERRIDE PREVENTION
The Backbone from Lakeport Metalcraft Inc. is a vertical metal bar designed to prevent serious and potentially fatal injuries to operators of reach trucks and standup forklifts caused by horizontal objects intruding into the operator's compartment. According to the device's manufacturer, most of these accidents occur during rearward collisions with racking—for example, when a horizontal rack beam penetrates the operator compartment.
The Backbone is easy to install and attaches in minutes, according to the manufacturer. It also complies with the ANSI B56.1 safety standard for lift trucks and meets the requirement to withstand the impact of a fully loaded truck traveling 1.6 km/h, or approximately 1 mph. (Lakeport Metalcraft Inc., www.lakeportmetalcraft.com)
DOCK SAFETY COMMUNICATION SYSTEM
When used in concert with its Dok-Lok vehicle restraint system, Rite-Hite's Corner-Vu, Leveler-Vu, Pedestrian-Vu, and new Approach-Vu warning systems make forklift operators and pedestrians aware of lift truck activity in and around loading and receiving docks as well as inside truck trailers, improving safety for everyone.
Corner-Vu lights (see photo) are located on the upper corners of the interior dock door, without obstructing the forklift driver's view. A green light means the trailer is safely secured to the loading dock with a Dok-Lok restraint, while a red light indicates the trailer is not secured and is unsafe to enter. Corner-Vu lights also serve as a reference point for the overhead door opening.
Leveler-Vu helps prevent accidents by conveying Dok-Lok status to the forklift operator while he or she is inside the trailer. A green light means the trailer is safely secured to the loading dock with a Dok-Lok restraint. A red light indicates the trailer is not secured. The lights also serve as a reference point of the leveler location for the lift truck operator when backing out of the trailer. Leveler-Vu lights mount into the back of the leveler in the standard weather-seal channel and are positioned below the surface of the leveler, preventing direct contact with forklifts.
Pedestrian-Vu communicates to pedestrians and material handling equipment operators on the dock that there is activity inside a trailer. Motion sensors are located on each side of the dock door and are aimed inside the trailer; an intense flashing blue light is emitted onto the dock leveler when motion is detected inside the trailer. Pedestrian-Vu also works in conjunction with Dok-Lok to alert any dockworker or forklift that enters an unsecured trailer. The blue light flickers as an audible alarm alerts the worker that he or she has entered an unsecured trailer, while the external light system simultaneously changes to red, warning the truck driver that there is activity inside the trailer.
Outside the dock opening, from a fixed location above the dock door, the Approach-Vu sensor detects the motion of a tractor-trailer backing into a dock position. A visual and audible alarm located on the Dok-Lok vehicle restraint alerts dock workers and pedestrians of the impending danger. According to the manufacturer, this multisensory alert system is important because ambient noise often masks the sound of a cab's engine, which can be 70 feet or more from the back of the trailer. (Rite-Hite, www.rite-hite.com)
LED FORKLIFT WARNING LIGHT
Industrial lighting expert Larson Electronics LLC has released the EXHL-TRN-RPS-LE4-FKWL-BLU-M, a new 25-watt rechargeable blue LED forklift warning light. The unit produces 2,250 lumens of intense blue light that is visible both during the day and at night to indicate the forklift's pathway, warning pedestrians of ongoing forklift operation.
The explosion-proof light operates on a rechargeable lithium-ion battery with eight hours of runtime. An unbreakable polycarbonate lens covers the light. The unit's housing, constructed of extruded aluminum, is waterproof to three meters and is resistant to dust, dirt, and humidity. The light can operate in temperatures of minus 40 degrees C to 60 degrees C (minus 40 degrees F to 140 degrees F), and is resistant to shock and vibration. An adjustable magnetic mount allows operators to control the tilt and rotation of the LED. (Larson Electronics LLC, www.larsonelectronics.com)
ARC SAFETY LIGHT
According to Panacea Aftermarket Co., its exclusive patent-pending LED forklift arc safety light is the world's first. When used in conjunction with the company's red zone forklift safety lights, the light provides 75 times the coverage of standard blue forklift lights, the company says.
The safety light projects a wide, brightly colored line around the front, back, and sides of the truck, with forward and rear projection of eight to 12 feet. It is available in 12 to 80 volts and three colors: red, blue, and green. With an IP67-rated aluminum housing, the arc light comes with a lifetime warranty. (Panacea Aftermarket Co., panaceaco.com)
FORKLIFT SAFETY AND LOAD PROTECTION PRODUCTS
Australia-based SumoSafe Global says it offers a range of "ingeniously simple yet highly innovative" products that significantly reduce damage to palletized loads, making forklift trucks safer to operate.
The SumoSafe lineup includes:
SumoSafeforks—a radical new design of lift truck fork that takes traditional steel tines and encases the tips within a protective glove. Made from industrial-grade polyurethane, the glove limits the impact of a carelessly driven lift truck's forks against a load.
SumoGloves—a variation on the SumoSafefork. SumoGloves are quickly and easily fitted to the tips of a lift truck's existing forks. They are compatible with all common makes and sizes of forklift tines.
SumoVision—a system that improves an operator's forward visibility even when sightlines are obscured by a large bulky load.
SumoLevel—a new forklift mast-tilt indicator system that reduces accidental damage to pallets, loads, and racking caused by a lift truck's forks during pallet picking and putaway.
SumoBackbone—a protective device that can be retrofitted to any lift truck make or model to minimize the risk of an operator's suffering a spine or whiplash injury from reversing into a stationary object or being hit from the rear by another forklift. (SumoSafe Global, www.sumosafe.net)
COLLISION ALERT SYSTEM
Sensor solutions provider Sick's backup assistance system (BAS) is a stand-alone aftermarket solution that actively alerts the operator to unseen obstructions behind the forklift, which contributes to a reduction in accidents.
Using the manufacturer's compact, advanced laser measurement scanner, the backup assistance system gives real-time feedback to the driver via an audible warning only when the truck is too close to any stationary or moving object. This intelligent system, which was designed specifically for forklifts, can be connected to the reverse-drive function of the vehicle to eliminate false alarms. Kits are available for different-voltage trucks and electrical systems, the company says. (Sick Inc., www.sickusa.com)
SAFETY-DATA COLLECTION BELT
Modjoul Inc.'s SmartBelt improves safety by tracking forklift drivers' actions and identifying risky behaviors that could lead to safety incidents. The wearable SmartBelt uses sensors and a geographic positioning system (GPS) to gather data about location, motion, and environment, giving companies information that can help them understand behaviors and activities that lead to injuries, the manufacturer says.
Data are collected based on counts, duration, and rate of the employee's activities, including walking, sitting, falling, driving, bending, and tripping. The SmartBelt transmits the data to the cloud via Wi-Fi, and the information is reported in three customizable dashboard views: CEO, Supervisor, and Employee. The dashboard reports allow the viewer to see an overview and ranking of an employee's safety as well as to look at specific events and track an employee's location. The software allows the owner to go back in time to review the data leading up to and following an incident.
Available in sizes from 30 to 44 inches, the SmartBelt uses vibrations to send alerts from a supervisor to the wearer. If the wearer encounters a problem, an alert button located on the bottom of the SmartBelt buckle can be used to notify a supervisor via Wi-Fi and the Modjoul mobile app. The SmartBelt has a battery life of up to 12 hours; charging at the end of every shift is recommended. (Modjoul Inc., www.modjoul.com)
Congestion on U.S. highways is costing the trucking industry big, according to research from the American Transportation Research Institute (ATRI), released today.
The group found that traffic congestion on U.S. highways added $108.8 billion in costs to the trucking industry in 2022, a record high. The information comes from ATRI’s Cost of Congestion study, which is part of the organization’s ongoing highway performance measurement research.
Total hours of congestion fell slightly compared to 2021 due to softening freight market conditions, but the cost of operating a truck increased at a much higher rate, according to the research. As a result, the overall cost of congestion increased by 15% year-over-year—a level equivalent to more than 430,000 commercial truck drivers sitting idle for one work year and an average cost of $7,588 for every registered combination truck.
The analysis also identified metropolitan delays and related impacts, showing that the top 10 most-congested states each experienced added costs of more than $8 billion. That list was led by Texas, at $9.17 billion in added costs; California, at $8.77 billion; and Florida, $8.44 billion. Rounding out the top 10 list were New York, Georgia, New Jersey, Illinois, Pennsylvania, Louisiana, and Tennessee. Combined, the top 10 states account for more than half of the trucking industry’s congestion costs nationwide—52%, according to the research.
The metro areas with the highest congestion costs include New York City, $6.68 billion; Miami, $3.2 billion; and Chicago, $3.14 billion.
ATRI’s analysis also found that the trucking industry wasted more than 6.4 billion gallons of diesel fuel in 2022 due to congestion, resulting in additional fuel costs of $32.1 billion.
ATRI used a combination of data sources, including its truck GPS database and Operational Costs study benchmarks, to calculate the impacts of trucking delays on major U.S. roadways.
Hyster-Yale Materials Handling today announced its plans to fulfill the domestic manufacturing requirements of the Build America, Buy America (BABA) Act for certain portions of its lineup of forklift trucks and container handling equipment.
That means the Greenville, North Carolina-based company now plans to expand its existing American manufacturing with a targeted set of high-capacity models, including electric options, that align with the needs of infrastructure projects subject to BABA requirements. The company’s plans include determining the optimal production location in the United States, strategically expanding sourcing agreements to meet local material requirements, and further developing electric power options for high-capacity equipment.
As a part of the 2021 Infrastructure Investment and Jobs Act, the BABA Act aims to increase the use of American-made materials in federally funded infrastructure projects across the U.S., Hyster-Yale says. It was enacted as part of a broader effort to boost domestic manufacturing and economic growth, and mandates that federal dollars allocated to infrastructure – such as roads, bridges, ports and public transit systems – must prioritize materials produced in the USA, including critical items like steel, iron and various construction materials.
Hyster-Yale’s footprint in the U.S. is spread across 10 locations, including three manufacturing facilities.
“Our leadership is fully invested in meeting the needs of businesses that require BABA-compliant material handling solutions,” Tony Salgado, Hyster-Yale’s chief operating officer, said in a release. “We are working to partner with our key domestic suppliers, as well as identifying how best to leverage our own American manufacturing footprint to deliver a competitive solution for our customers and stakeholders. But beyond mere compliance, and in line with the many areas of our business where we are evolving to better support our customers, our commitment remains steadfast. We are dedicated to delivering industry-leading standards in design, durability and performance — qualities that have become synonymous with our brands worldwide and that our customers have come to rely on and expect.”
In a separate move, the U.S. Environmental Protection Agency (EPA) also gave its approval for the state to advance its Heavy-Duty Omnibus Rule, which is crafted to significantly reduce smog-forming nitrogen oxide (NOx) emissions from new heavy-duty, diesel-powered trucks.
Both rules are intended to deliver health benefits to California citizens affected by vehicle pollution, according to the environmental group Earthjustice. If the state gets federal approval for the final steps to become law, the rules mean that cars on the road in California will largely be zero-emissions a generation from now in the 2050s, accounting for the average vehicle lifespan of vehicles with internal combustion engine (ICE) power sold before that 2035 date.
“This might read like checking a bureaucratic box, but EPA’s approval is a critical step forward in protecting our lungs from pollution and our wallets from the expenses of combustion fuels,” Paul Cort, director of Earthjustice’s Right To Zero campaign, said in a release. “The gradual shift in car sales to zero-emissions models will cut smog and household costs while growing California’s clean energy workforce. Cutting truck pollution will help clear our skies of smog. EPA should now approve the remaining authorization requests from California to allow the state to clean its air and protect its residents.”
However, the truck drivers' industry group Owner-Operator Independent Drivers Association (OOIDA) pushed back against the federal decision allowing the Omnibus Low-NOx rule to advance. "The Omnibus Low-NOx waiver for California calls into question the policymaking process under the Biden administration's EPA. Purposefully injecting uncertainty into a $588 billion American industry is bad for our economy and makes no meaningful progress towards purported environmental goals," (OOIDA) President Todd Spencer said in a release. "EPA's credibility outside of radical environmental circles would have been better served by working with regulated industries rather than ramming through last-minute special interest favors. We look forward to working with the Trump administration's EPA in good faith towards achievable environmental outcomes.”
Editor's note:This article was revised on December 18 to add reaction from OOIDA.
DAT Freight & Analytics has acquired Trucker Tools, calling the deal a strategic move designed to combine Trucker Tools' approach to load tracking and carrier sourcing with DAT’s experience providing freight solutions.
Beaverton, Oregon-based DAT operates what it calls the largest truckload freight marketplace and truckload freight data analytics service in North America. Terms of the deal were not disclosed, but DAT is a business unit of the publicly traded, Fortune 1000-company Roper Technologies.
Following the deal, DAT said that brokers will continue to get load visibility and capacity tools for every load they manage, but now with greater resources for an enhanced suite of broker tools. And in turn, carriers will get the same lifestyle features as before—like weigh scales and fuel optimizers—but will also gain access to one of the largest networks of loads, making it easier for carriers to find the loads they want.
Trucker Tools CEO Kary Jablonski praised the deal, saying the firms are aligned in their goals to simplify and enhance the lives of brokers and carriers. “Through our strategic partnership with DAT, we are amplifying this mission on a greater scale, delivering enhanced solutions and transformative insights to our customers. This collaboration unlocks opportunities for speed, efficiency, and innovation for the freight industry. We are thrilled to align with DAT to advance their vision of eliminating uncertainty in the freight industry,” Jablonski said.
Global trade will see a moderate rebound in 2025, likely growing by 3.6% in volume terms, helped by companies restocking and households renewing purchases of durable goods while reducing spending on services, according to a forecast from trade credit insurer Allianz Trade.
The end of the year for 2024 will also likely be supported by companies rushing to ship goods in anticipation of the higher tariffs likely to be imposed by the coming Trump administration, and other potential disruptions in the coming quarters, the report said.
However, that tailwind for global trade will likely shift to a headwind once the effects of a renewed but contained trade war are felt from the second half of 2025 and in full in 2026. As a result, Allianz Trade has throttled back its predictions, saying that global trade in volume will grow by 2.8% in 2025 (reduced by 0.2 percentage points vs. its previous forecast) and 2.3% in 2026 (reduced by 0.5 percentage points).
The same logic applies to Allianz Trade’s forecast for export prices in U.S. dollars, which the firm has now revised downward to predict growth reaching 2.3% in 2025 (reduced by 1.7 percentage points) and 4.1% in 2026 (reduced by 0.8 percentage points).
In the meantime, the rush to frontload imports into the U.S. is giving freight carriers an early Christmas present. According to Allianz Trade, data released last week showed Chinese exports rising by a robust 6.7% y/y in November. And imports of some consumer goods that have been threatened with a likely 25% tariff under the new Trump administration have outperformed even more, growing by nearly 20% y/y on average between July and September.