Client Challenge:

Synlait, a food manufacturing facility, needed to improve pedestrian safety in risk areas and ensure that expensive assets — such as forklift chargers and electrical cabinets—were protected from potential forklift impacts.

Key challenges they faced:

• Unsafe pedestrian zones: Existing pedestrian exit points were not clearly separated from vehicle traffic, creating potential safety risks for staff exiting the facility.
• Asset protection concerns: Expensive forklift chargers and electrical cabinets were vulnerable to damage from moving machinery, risking costly repairs and operational disruptions.
• Space constraints: Solutions needed to fit within tight working areas without obstructing traffic flow or day-to-day operations.

Solutions Recommended

To fully understand the challenges and objectives, a Vanguard consultant visited the Synlait site, met with the operations and H&S managers, and conducted a walk-through of the facility to assess their areas of concern. This allowed us to ensure the solutions we recommended were fit-for-purpose and would achieve the outcomes they were looking for.

The following solutions were implemented:

Aluminium Handrail

• • Why: Segregated pedestrian areas were created without compromising space. The small footprint of this handrail system ensured walkways were protected without getting in the way of site operations.

Surface Mounted Steel Bollards

• • Why: Installed to protect electrical cabinets from potential forklift collisions. These bollards provided a physical barrier to prevent costly damage to critical assets.

1650mm Rubber Wheel Stops

• • Why: Positioned as a stopping point for forklifts to prevent them damaging the forklift chargers. The rubber material absorbs impact and acts as a sacrificial element—reducing the risk of damage to high-value equipment and lowering long-term repair costs.

The Outcome

As a result of these solutions, Synlait was able to achieve:

• Safe pedestrian zones, ensuring staff could exit the facility without risk from moving vehicles.
• Enhanced asset protection, with forklift chargers and electrical cabinets now protected from potential impacts.
• Cost savings, by proactively preventing damage to expensive equipment and minimizing operational downtime.

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