TL; DR
- The Challenge: Forklifts were operating too close to employee work areas in the paper-roll warehouse, creating ongoing collision risk.
- The Solution: By implementing ELOshield, the company introduced a preventive forklift safety system that improved awareness, supported drivers and pedestrians with real-time alerts, and added vehicle intervention capabilities when needed.
The project at a glance
Close-quarter working environment
Daily risk to pedestrians
Multiple Shifts
Increased Fateague
31
Pedestrian Wearables
3
ELOshield truck modules
Dunapack Case Study Video Transcription
Since the introduction of ELOshield, all employees have been moving through the paper roll warehouse with increased awareness.
Avoidance of near misses, avoidance of workplace accidents and all of this with a very high level of comfort.
Our biggest challenge was that the roll clamp trucks in our paper roll warehouse operate very close to the work environment, where employees are present, creating a high risk of collision.
ELOshield offers the possibility to solve many problems at once.
ELOshield works with ultra-wideband technology and with the help of the ELOshield system, we can intervene in vehicles, meaning we can reduce speed, for example to prevent vehicle-to-vehicle or vehicle-to-person collisions.
I think it works very well here in practice because people with their pedestrian module receive a signal when they enter the driving area, and I also have a display in the forklift that shows two different colors, green and red, which allows me to react and know which zone the person is in.
Toward the end of shifts, attention tends to drop, and now we have found a way with ELOshield to integrate a system that continuously reminds employees:
"Attention, there is currently a person in your work area."
Furthermore, ELOshield can be combined with all other ELOKON products.
This means we can combine ELOshield with our fleet management system to identify within the fleet whether damage has occurred or a warning was triggered.
We can combine it with ELOvision and with all products available at ELOKON.
The modular design is the key feature that makes ELOshield integrable into all other systems. And all of this at a very cost-effective price, completely independent of OEMs.
The system itself is highly configurable and adaptable to 99.9% of all warehouse environments.
We use ELOshield in Linde H80 forklifts. In addition, we have also installed ELOvision in the forklifts, which has also been very positively received by the employees.
At the beginning, many were skeptical about what this system was like. But many got used to it quickly, even the biggest skeptics, because it is truly helpful, especially during night shifts.
When attention sometimes drops, you get a signal, a sound, and you know exactly something is there. You instantly become fully alert and pay attention. I think it has brought a lot of safety.
We have provided preventive safety before accidents happen. Unfortunately, that is not always the case, but at Dunapack we were able to do it on time. That was very important.
My collaboration with ELOKON has been consistently positive. It started with video calls where we discussed initial solution approaches and then refined them during an on-site appointment.
I can recommend this system to any company where people and machines operate very close to each other and where there is a real risk of collisions.
The Challenge: Forklifts and Pedestrians Working in Close Proximity
Like many material handling environments around the world, Dunapack’s paper-roll warehouse depends on efficient forklift movement to keep operations running smoothly. But that efficiency came with a safety challenge.
According to the Dunapack team, roll forklifts would often come extremely close to pedestrian working areas. That created a high-risk environment where even a brief lapse in awareness could result in a near-miss or a more serious incident.
The challenge became even more pressing toward the end of shifts and during night operations, when alertness can naturally decrease.
With no warehouse safety systems in place, Dunapack needed a warehouse collision prevention solution that would improve employee awareness in real time without adding friction to their daily warehouse operations.
"The assistance system has been a complete success. The entire team fully endorsed the project and now feels safer in their working environment," said the warehouse manager. ELOshield’s functional diversity was a particularly strong selling point as it enabled an individual security concept to be devised for each separate area.
The Solution: A Real-Time Forklift Pedestrian Detection System with Alerts
Dunapack chose the ELOshield forklift collision avoidance system to bring proactive safety into their warehouse before accidents could occur.
ELOshield is an ultra-wideband (UWB) forklift proximity detection safety system that detects and alerts when pedestrians or vehicles breach custom defined safety zones.
The solution delivers real-time alerts to both pedestrians and forklift operators. This instantaneous alert system makes it easier for warehouse employees to avoid dangerous situations.
- For Pedestrians: The personal module delivers audible, visual, and haptic alerts as soon as they breach a custom defined warning zone.
- For Forklift Drivers: An in-vehicle module delivers audible and visual alerts in real-time, helping them quickly understand where another person or vehicle is and respond appropriately.
The UWB technology powering the ELOshield forklift safety solution can detect pedestrians and vehicles through racks, behind pallets and other obstacles, or around blind spots.
The system can also be configured to intervene directly by reducing forklift speed, further increasing forklift accident prevention.
The Results: Greater Awareness, Proactive Safety, and Seamless Integration
While Dunapack did not share numerical KPIs, the team described several clear results they experienced after deploying ELOshield in its warehouse operation:
- Increased employee awareness throughout the paper-roll warehouse
- Better prevention of near-misses and workplace accidents
- Real-time alerts for both pedestrians and forklift operators
- Preventive safety measures before an incident happens
- Strong employee adoption after initial skepticism
- High comfort for users alongside improved safety
One of the biggest benefits was that Dunapack was able to put a preventive safety system in place before an accident occurred.
Because it really is helpful, especially on the night shift. When your attention sometimes starts to drop, you simply get a signal, a sound, and you know right away that something is going on. In that moment, you become wide awake and really pay attention. I think it has made things a lot safer.
That proactive step is especially important in environments where people and machines work closely together.
A Scalable, Modular Warehouse Safety Ecosystem
Another advantage for Dunapack was ELOshield’s ability to integrate with other ELOKON solutions, giving them a more connected warehouse safety and fleet visibility ecosystem.
At Dunapack, the optical and acoustic warnings from our ELOvision product were used in addition to the safety features found in ELOshield. They really liked the additional layer of safety and appreciated that they not only had a pedestrian warning on board, but also a rear-view camera now
The company also noted ELOshield’ sability can be linked with a fleet-management system – like ELOfleet - to help streamline access control, safety checklists, impact monitoring and fleet hygiene data.
According to Dunapack, this modular design was a key strength.
They described the system as:
- Highly configurable
- Adaptable to nearly any warehouse environment
- OEM-agnostic
- Cost-effective
- Easy to integrate with existing systems and infrastructure
For operations and safety leaders looking for flexible warehouse safety technology, that combination of configurability and integration is a major advantage.
Streamlined Implementation and Collaboration
Dunapack also highlighted the implementation process as a positive part of the project.
Their collaboration with ELOKON began with video calls focused on initial solution concepts. From there, the teams refined the approach through on-site visits and further review.
This cooperative planning and refinement helped ensure the final setup matched the realities of the warehouse and the safety needs of the operation.
This highly collaborative rollout approach that ELOKON is known for helped streamline both system installation and support employee adoption.
The Customer Perspective
Industrial environments where forklifts and pedestrians operate in close proximity need more than signage and policies alone. Dunapack needed elevated safety standards that include real-time awareness and proactive incident avoidance.
ELOshield is particularly valuable for material handling companies that want to:
- Improve forklift and pedestrian safety in warehouses
- Reduce the risk of collision in mixed-traffic environments
- Enhance employee awareness during high-fatigue shifts
- Add a configurable, OEM-agnostic safety system
- Integrate forklift safety with fleet management and visibility tools
Dunapack’s recommendation was clear: the ELOshield system is a strong fit for any company where people and machines work close together, and there is a real risk of contact between them.
That endorsement reflects the core value of the ELOshield product: a practical, configurable warehouse safety solution that helps teams stay alert, react faster, and reduce risk before incidents occur.
Conclusion
The outcome for Dunapack was a safer, more proactive warehouse environment—one that helped employees stay focused & alert, improved comfort with daily operations, and brought modern collision avoidance technology into a high-risk setting.
If your warehouse has pedestrians and forklifts sharing the same space, Dunapack’s experience shows how a configurable system like ELOshield can help turn safety from a reactive process into a preventive one.
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