Forklifts run through tight aisles, mixed worker paths, and shifting pallet stacks for long stretches, so operators deal with visual strain throughout the day. Industry reports show 75 to 100 workers lose their lives annually due to forklift accidents, with an average of 87 deaths per year. While this highlights how limited visibility influences high-risk moments, the reality is that 70% of forklift accidents can be prevented through trustworthy vision systems.
Daily Warehouse Challenges That Disrupt Forklift Awareness
Forklift movement introduces multiple points of pressure on visibility. Loads rise above eye level, racks compress lateral views, and glare from polished floors interrupts depth cues. Workers enter shared paths frequently, and clutter builds during fast-paced receiving cycles. Is it any surprise that warehouses report over 34,900 serious injuries annually?
Imaging challenges faced by forklifts:
•Workers stepping into aisle lines during pallet flow
•Pallets leaning or parked off-angle near dock edges
•Tall racks forming dark pockets during turning
•High-gloss flooring producing strong glare patches
Why Forklifts Need a Rugged, GigE Industrial Camera
Forklifts shake, tilt, and pivot through every cycle, so the camera must hold stable clarity during vibration-heavy travel. Lighting shifts quickly while moving between racks, open yards, and staging areas. e-con Systems’ advanced RouteCAM camera series ensures superior imaging performance in these conditions, offering accurate visual awareness for operator support and warehouse safety.
It includes features such as global shutter, wide FoV, HDR, on-board ISP, PTP time & frame synchronisation, and IP67-rated enclosures. RouteCAM cameras are also compatible with CloVis Central™ – e-con Systems’ cloud-based device management platform.
Popular use cases:
•Pallet pickup and placement where edge visibility guides alignment
•Constant worker movement across shared aisle paths
•Cornering through tight bends that obscure sightlines
•Navigation through glare-heavy flooring zones
•Reversing near loading docks and staging areas
e-con Systems also offers ForkVista, an AI-based GigE camera for improving forklift safety. It comes with AI and ML-powered human recognition capabilities such as real-time video analysis and alerts, low latency detection, and customisable intrusion detection zones.
How e-con Systems’ GigE Industrial Cameras Ensure Forklift Safety
•Builds clearer spatial awareness that supports accident avoidance
•Helps operators detect movement earlier in high-traffic zones
•Provides stronger depth cues during mast elevation
•Reduces visual blind spots around racks and pallet stacks
•Supports smoother manoeuvring in areas with uneven lighting
Interested in knowing more? Please write to camerasolutions@e-consystems.com.
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