As global competition increases and the consumer mindset of “faster is better” takes over business, companies are under a time pressure to ensure their products are sorted and delivered to their end users.
Many companies have added systems of multi-level pick modules with flow lanes to quickly move palletized products through while they also maximize their available space. These pallet flow lanes are often loaded from one side of the pallet racking and picked from the other side. As each load is removed a pallet load from behind automatically moves into position for picking.
These systems can be very complex, with multiple flow lanes within the rack system. Often employees are working to pick pallets from these systems, which can be located on elevated platforms. When employees work from these elevated levels in picking operations, safety is of utmost importance to keep them from falling off the ledge.
Although by design the picker is positioned a safe distance from the ledge, there is still an egress to the ledge so it must be secured. Often the entire lane is decked over for safety so the picker and palletized items don’t fall between the lanes. However, this creates another safety concern because the employees have access to enter the lanes, often to retrieve a dislodged item, or to square up a pallet, or simply because they can. Because of these concerns, we recommend decking the entire lane to move the ledge out to the end of the module. Then, the ledge should be secured with a gate system that allows pallets to enter the lane but prevents employees from falling.
We recommend two solutions. The first is our Pallet Flow Safety gate, which is a self-closing swing gate designed specially for pallet flow applications. It uses solid panel gates to allow the lift truck to push the gates open with the pallet and creates a smooth transition for the pallet to flow down the lane. Tension-adjustable hinges allow the gates to automatically close, and and heavy-duty welded stops prevent the gates from swinging outward, creating a fall-protection barrier.
The second solution, created to meet updated ANSI standards, is a gate system for pallet flow lanes that uses dual counterbalanced and interconnected gates to maintain a safe environment for employees at all times. One gate is positioned at the ledge, the second pallet in front of the first-pallet position where the picker is located. When the pallet flow side of the gate opens, the rear gate automatically closes, keeping the pickers away from the ledge and lane while pallets are deposited. To gain access the the lane, the picker raises the rear-side gate, which closes the ledge-side gate. This is the safest method of securing pallet flow lanes.
The system can be made as deep as the lane, and it not only keeps the employees secured from the elevated ledge, but it also prevents the lift truck from loading a pallet while an employee is in the lane, where a pallet could be pushed into his or her leg. The closed ledge-side gate becomes a signal that the lane should not be loaded. The lift truck can only load the lane when the picker closes the gate near them, which opens the ledge side gate – a signal to the driver below that the area is safe and ready to be replenished.
As your facility is updated to speed operations or maximize space, it’s always important to keep safety for your workers at top of mind. We are always working to ensure our safety gates keep up with new material handling technology and systems, and it’s important facility mangers do the same.
Chemical manufacturing facilities often have space issues when it comes to safety. Many of these plants have large reactors or mixers with hoppers accessed by elevated platforms positioned near the top of the vessels. Typically a lift truck will load pallets of ingredients onto these upper levels for employees to load into these mixers. So while positioned near a ledge, often unguarded, they are asked to remove heavy bags from a pallet, slice them open and pour them into the large mixer.
Space is often limited on these platforms so that the mixer is located near the pallet of ingredients to limit the distance the operator has to travel with a heavy bag. Often the area consists of a series of catwalks and small mezzanines around the mixer and the production machinery. This limited space is often an issue, leaving very little room for employee, product and proper fall protection guarding, which can expose employees to a high risk for incidents like falls.
We worked with a global manufacturer that works with chemicals to secure three areas in its facility. Each area featured a mixer with a set of platforms and catwalks on which employees were handling and creating the product.
The three platforms offered the additional challenge of very tight space constraints. The pallet drop areas were loaded with a lift truck, and safety relied upon a piece of chain to restrain people — not enough to keep employees safe.
This application is fairly common, outside of the manufacturer’s unique space constraints. All pallet drop areas on elevated platforms need to be properly guarded, but areas on production platforms where employees are asked to work around the ledge, often in a hostile environment, need to be taken seriously. This is often tiring, repetitive work in a dusty or wet environment so companies must take safety out of employee’s hands, giving them one less thing to think about during the day.
Due to the complexity of the areas that needed to be secured, custom dual-gate safety solutions were created. The first area had little room to accommodate a safety barrier so the gate had to be worked into the existing framework of the platform. A custom Pivot Gate was created to be affixed to the handrail instead of the walkway floor to provide dual-gate protection while taking up a minimum amount of space.
The second area pallet drop area had special requirements because a 48-inch pallet had to be able to rotate 360 degrees on a pallet turntable within the guarded area. This area offered additional challenges: there was low overhead, it was situated on a traffic aisle so there were very specific ways the lift truck entered the platform, and the equipment and a ramp to the mixer infringed on how the gate could be used. We created a custom version of High Pallet Pivot model, a dual-gate system that included 14 pivot points that extended the depth and width to accommodate the pallet. The system allowed the pallet to rotate on a turntable, ensuring ease of work and safety on the platform.
The third area had even less available depth due to the location of the blending hopper, which was positioned close to the ledge so the employee could simply turn and dump the bag of ingredients from the pallet into the hopper without carrying the bag. The limited available depth didn’t provide adequate room for a more traditional dual-gate system like the Pivot Model. We installed our Tri-Side design, which uses a fixed support frame only 14” deep, and a rear-side gate that raised up and out of the way when the ledge-side gate was closed, allowing access around the pallet. With this system in place, the employee could grab the bags around the pallet and dump them freely into the hopper, all while a barrier was in place at the ledge to prevent a fall.
All of these dual-gate systems we created - as well as hundreds of other solutions we have created - have worked to keep employees safe on the elevated platforms, as well as meet ANSI standards - while keeping operational processes intact.