Glencore implements lift truck, pedestrian safety system

Workplace safety is top of mind for about 85% of companies right now, according to PwC, which points to the manufacturing sector as one area where repetitive tasks and actions can be “physically taxing.” Accidents and injuries can also have devastating consequences for associates and employers, leading to lost productivity, fines and reputational damage.

Recently, global commodity trading and mining company Glencore wanted to reduce the number of safety incidents involving forklifts at its recycling facility in Rhode Island, where 35 employees work at shredding electronic materials, reducing particle size, and preparing samples for smelting and refining at the company’s recycling facility.

Glencore is a major recycler of end-of-life electronics, lithium-ion batteries, and other critical metal-containing products. They have long been closing the loop for critical metals like copper, nickel, cobalt, zinc and precious metals.

The electronics recycling process has also changed significantly over the years, forcing Glencore to continually adapt and tweak its processes. Modern electronics are mixed with various materials, complicating sampling and preparation. This complexity, combined with the high volume of forklift traffic and the close proximity of pedestrians in a relatively small environment, presented safety challenges that required a proactive technical solution.

Forklift-related accidents were a notable concern for the recycler. In 2021, for example, one unfortunate incident occurred between an employee and a forklift. No one was injured, but this accident underscored a need for better safety measures and technology to prevent these incidents in the future. The concern is valid: according to the National Safety Council, forklifts were the cause of 73 work-related deaths in 2022 and 24,960 non-fatal injuries in 2021 to 2022.

Glencore selected ELOshield proximity detection system (ELOKON). The supplier makes automated forklift safety and fleet management systems. Glencore chose ELOshield to retrofit its forklifts due to the system’s advanced warning capabilities, especially in areas with limited visibility.

Glencore equipped all five forklifts and personnel, including visitors, with ELOshield, which uses two-way ranging ultra-wideband (UWB) proximity detectors to warn lift truck operators when any pedestrians, objects or other vehicles are too close.

The system’s adjustable alert distances allowed for customized safety zones tailored to specific facility needs. This flexibility ensured comprehensive protection for everyone on site.

By prioritizing workplace safety, Glencore is protecting its employees, enhancing its reputation as an employer that puts its associates first, and fostering an overall more productive and positive work environment.

“Since we installed ELOshield, we haven’t had any significant incidents involving forklifts,” says Glencore plant manager Juan Carlos Molines. “The system has increased everyone’s awareness and hazard perception, making our facility much safer.”

The system’s ability to alert both lift truck operators and pedestrians has heightened overall safety awareness in the facility. This solution has not only reduced the number of incidents but also improved the general hazard perception among employees.