Yale Lift Truck Technologies has launched lithium-ion batteries with compatible chargers, specifically designed for selected Yale® pallet trucks, stackers, reach trucks, lift trucks, and other warehouse models. The unified solution of battery, charger, and materials handling equipment delivers smart energy for smart operations, and makes it simpler to acquire and maintain everything needed for a powerful and productive fleet from a single source – the global network of Yale dealer partners.
Validated as a fully-integrated system, the complete solution from Yale is designed to reduce compatibility challenges, all while providing a high-performance, maintenance free option that supports peak warehouse efficiency and reliability.
“Today’s warehouse challenges require smart thinking. With the unified lithium-ion battery and charging solutions installed, we are able to help operations bridge productivity gaps, and with the improvements in system efficiency, reduce the demands put on their facilities and power sources,” David LeBlanc, President, Energy Solutions, Yale Lift Truck Technologies explains. “With rising labour costs, energy costs, and new sustainability goals, the combination of lithium-ion power and Yale precision can deliver big business benefits.”
High performance battery technology supports quiet, clean operation in the warehouse. With the new lithium-ion options, there are no harmful gases, no need for battery rooms, and chargers can be placed in high-traffic areas to encourage opportunity charging.
The operator-friendly design also makes charging straightforward. Easy-access portals mean that the operator will not need to open the hood to charge the batteries. Built in interlock sensors prevent driving while plugged in.
With a high energy density, the new Yale lithium-ion batteries are well suited to demanding, multi-shift operations, such as those in 3rd party logistics warehouses or distribution centres. The batteries are designed to support uptime, with rapid charging and high-power output.
The new solution also helps elevate communications between batteries, chargers, and the lift truck. Yale Battery Vision telemetry is integrated, supporting efficiency by empowering fleet and service managers with access to real-time battery and lift truck data. The unified power systems remain seamlessly connected through updates and continuous syncing to support long-term compatibility and optimal performance.
To enable warehouse operations to scale battery and charging solutions and technologies to best meet their specific requirements and upgrade fleets easily, various battery box sizes and capacities are available. The batteries may also support sustainable asset management with a Battery Box Replacement (BBR) that enables second-life use.
“In many cases, adopting fast-charging lithium-ion lift trucks and equipment can keep warehouses moving at optimal efficiency,” says David. “However, this also relies on having the right support in place. That’s why Yale dealers are on hand to provide insight, advice, and solutions for businesses as they assess their fleet energy strategies. From battery selection and charger installation to warranty support and lifecycle management.”
In our latest episode of Logistics Business Conversations, we sit down with Yaro Tenzer, Co-Founder and CEO of RightHand Robotics, to explore the transformative role of robotics and AI in the logistics industry. As warehouses continue to evolve, the integration of advanced technologies is becoming essential for efficiency and reliability.
The logistics industry is on the brink of a technological revolution. With the rise of AI-driven automation, warehouses are transforming into high-efficiency hubs capable of handling complex fulfilment tasks with ease.
Key Insights:
AI and Automation: Discover how these technologies are enhancing throughput and reliability in high-demand environments. Innovative Solutions: Learn about the cutting-edge tools redefining item manipulation and fulfilment processes. Challenges and Opportunities: Explore the hurdles and potential of adopting robotic technology in logistics.
As the demand for faster and more reliable fulfilment grows, the role of robotics becomes increasingly crucial. With insights from Yaro Tenzer, this episode offers a glimpse into the future of warehousing, where “lights out” operations could become the norm, with robots working seamlessly around the clock.
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Spanish-based technology specialist Clustag is aiming for leadership in the RFID sector. Paul Hamblin spoke to Jorge Robledillo, North America Director, about the company’s products, successes and plans.
RFID is a word we see a lot, perhaps without understanding the term fully. Please explain what RFID is and why it is a transformational technology in logistics.
“RFID, or Radio Frequency Identification, is a technology that allows assets to be identified, tracked, and managed automatically and without direct visual contact, using radio waves. Unlike barcodes, which require manual scanning and a line of sight, RFID systems can read hundreds of items simultaneously, even when they’re inside closed boxes or in motion. This not only increases speed but also improves the accuracy of intralogistics processes.
“Within the RFID universe, there is RAIN RFID, a global standard based on UHF (Ultra High Frequency) technology that enables wireless communication between tags and readers with greater range and faster read speeds. RAIN RFID is the technology that makes possible many of the item-level traceability solutions used today in sectors such as retail, sports, fashion, cosmetics, and even healthcare.
“At Clustag, we work specifically with RAIN RFID because it forms the foundation for developing robust, scalable, high-performance solutions tailored to modern, automated, or semi-automated logistics centres. This is the technology that powers our mass scanning tunnels, our MOT stations, and all our integration with WMS, ERP, or e-commerce systems.
“Understanding RFID and RAIN is key to understanding what we do at Clustag: automating intelligently, optimising with precision, and providing real visibility into the flow of millions of products each day. From there, everything we do makes sense.”
That leads us nicely into Clustag. Tell us a bit more about the company.
“Clustag is much more than an RFID solutions provider. We design, manufacture, install, and support customised RFID solutions for all types of warehouses: from manual operations to highly automated centres.
“We are a global company specialising in advanced RFID and IoT solutions applied to intralogistics, traceability, and process digitalisation. Our main headquarters is in Valencia, Spain, and we have a direct presence in North America, with offices in Miami (where I spend most of my time) and a subsidiary in Puebla, Mexico. We currently operate in over 30 countries and have deployed more than 3,000 active RFID solutions.”
What is the Clustag point of difference?
“All our RFID solutions incorporate Zentup, our exclusive middleware that seamlessly integrates hardware and software, enabling total and secure control over data capture and management. This integration ensures that all collected information is accurate, reliable, and available in real time for decision-making.
“In addition, we have patented technology, RFID-Shield Technology, which prevents any kind of cross or unwanted reading between boxes – stray reading – even in the smallest spaces. This guarantees the highest precision in the identification and traceability of each item, eliminating errors and improving operational efficiency. Thanks to these innovations, our clients benefit from faster, safer processes with complete visibility over their inventory.”
And all this happens with a 100% focus on real integration with the client’s systems such as their ERP and WMS.
“Since day one, we have been committed to innovating where it matters most: precision, speed, and visibility. Today, our systems have processed more than five billion RFID tags and have achieved reliability levels above 99%.”
What does this precision, speed and visibility mean for the client?
“It means the ability to make decisions in real-time. Thanks to Zentup, our customers can see exactly the status of every item at every point in their operation.
“It also enables seamless integration of both hardware and software. Our implementations are agile and functional, designed to minimise any disruption and to ensure that daily operations continue smoothly without unnecessary interruptions.”
Could you talk us through some real-world examples of Clustag’s success with clients?
“At Clustag, we don’t make promises. We deliver results and provide tangible, sustainable outcomes in any sector. We minimise errors and inventory losses through automation, offer total real-time visibility for agile decision-making, ensure seamless integration with existing systems without disrupting operations, and optimise every logistical process, from inventory management to order fulfilment.
“All of this is achieved under strict security standards and regulatory compliance, resulting in cost savings, improved customer experience, and a true competitive advantage. Let’s start with an example from the retail fashion sector, with Sport Time, which distributes Nike products in some territories of Eastern Europe.
“To address the logistical challenges of sports distribution, Sport Time Group implemented Clustag’s parcel RFID Solution (MOT Station), powered by RFID-Shield Technology and Zentup, an advanced system that optimises post-picking control in its distribution centres.
“Post-picking RFID control: The MOT S20 scans items at order level as they are grouped into boxes, automatically detecting if any products are missing, if there are unexpected items, or unreadable tags.”
Automated audit: Boxes with discrepancies are diverted to an audit area, where operators use Zentup software to correct errors before shipping.
Full integration: The system connects Sport Time’s warehouse systems, enabling efficient inventory management and order preparation, even with multiple materials and references.
Results: There has been a significant improvement in order accuracy, a reduction in human errors, and greater speed and reliability in preparation for retail, wholesale, and e-commerce.
“Thanks to staff training and familiarisation with Zentup, Sport Time has optimised inventory management and raised the standard of efficiency in sports goods distribution in Eastern Europe.”
Our second example comes from the pharma and healthcare sector, focused on loan kits.
“In the rapidly evolving field of healthcare logistics, precision is essential. A major global pharmaceutical company faced significant challenges managing orthopaedic loan kits, which were often packed manually, shipped to hospitals, returned incomplete, and processed again, all while needing to maintain flexibility, inventory accuracy and proper billing.”
To address these issues, the company sought to establish a robust quality checkpoint system at every stage of the kit’s journey:
Outbound: kits scanned before leaving the warehouse. Hospital arrival: contents verified upon delivery. Return: kits scanned before being shipped back. Warehouse inbound: returned kits scanned to detect missing or incorrect items.
“If discrepancies arose, the system would need to flag them immediately, and any unreadable tags would need to be reprinted on the spot, eliminating delays and blind spots. This was crucial, as every missed tag could result in stock errors, surgical delays, or billing disputes. The company required a solution that would provide clarity, speed, and total control over a complex, high-volume process.
“The successful solution was provided by Clustag’s Standard RFID Solution (Massive Plus Station), powered by RFID-Shield Technology and Zentup, turning a manual, error-prone process into a streamlined, intelligent workflow. The solution delivered speed, accuracy, and traceability, proving that RFID can thrive even in non-automated environments.”
The future looks exciting. What’s next for Clustag?
“At Clustag, on a global level, we aim to be the global leaders in intelligent traceability solutions and advanced asset management.
“Under my leadership as North America Director, we are fully committed to innovation and to tackling every challenge our clients present to us, whether in pharma, food, fashion, or sports. Our ambition is to continue growing, launch new projects in more US states, and strengthen our presence throughout the country.
“We will be present at MODEX 2026 in Atlanta, after recently participating at Promat Chicago. We are determined to stay at the forefront, wherever the future of logistics is being shaped.
“But our real driving force is our ability to adapt and anticipate the needs of such diverse industries. At Clustag, we don’t just install technology, we transform operations, support our clients, and turn every challenge into an opportunity to innovate and grow together.
“Because being a leader means knowing where to go, why to go there, and having the determination to bring others along on the journey.”
For logistics operators, every peak season comes with high stakes. Order volumes spike, operations run nonstop, and both equipment and staff are stretched to their limits. With Christmas fast approaching, any disruption in roller conveyors can halt the entire process. One stall, and productivity drops, shipments pile up, and customer complaints start to mount.
Luca Zironda, Global ISM Material Handling & Automation Power Transmission Manager at Megadyne, tells us, “when demand spikes, roller conveyors never stop working. In this context, power transmission belt systems must meet rigorous criteria: reliability, durability, and efficiency. Critical to belt performance is its interaction with rollers: it must combine flexibility with optimised friction on metal rollers to ensure a smooth transport.”
“Achieving the right balance depends on the belt’s material and design.” He adds, “It must provide enough friction on the metal rollers to ensure the secure transfer of each package tray and low friction on the idlers to minimise energy consumption. A well-engineered belt that endures repeated bending cycles and maintains optimal friction levels is essential to keep intralogistics operations reliable and efficient.”
High-demand environments
Designed specifically for warehouses, MEGALINEAR Live Roller 45 mm is a durable, low-maintenance, and energy-efficient belt engineered to perform reliably during extended duty cycles. Manufactured from polyurethane 85° ShA, the belt is available in green, either in the standard version or in an alternative version with black antistatic fabric on the bottom surface.
Its key features include: • High-friction surface ensures reliable power transmission to the roller drive • Durable polyurethane and high-performance Kevlar® cords for nonstop duty cycles • Translucent PU body for easy wear detection • Antistatic fabric and polyurethane (on request) for extreme duty applications
The belt ensures high efficiency with minimal maintenance (it is typically delivered in open-ended rolls and can be customised and spliced directly on-site by warehouse maintenance teams), energy savings, and lower total costs.
The right belt for every Peak Season
When reliability is non-negotiable, every component plays a role in keeping goods moving. Megadyne MEGALINEAR MLR 45 delivers consistent performance under pressure, making it the most dependable choice for uninterrupted flow during any peak season.
CEVA Logistics, a subsidiary of the CMA CGM Group, has signed a new multi-year agreement with Ferrari to continue its logistics relationship as Official Logistics Provider and Premium Partner of both Scuderia Ferrari HP and — new for 2026 — Ferrari Hypercar.
Under the new contract, CEVA will continue to manage comprehensive logistics for Scuderia Ferrari HP while adding support to Ferrari’s Hypercar motorsports activities. CEVA’s support includes routing, transport modes, transport provider selection, customs clearance and emergency protocols — all with a vision to propose more sustainable, low carbon solutions and reduce emissions.
Since 2022, CEVA teams have partnered collaboratively with Scuderia Ferrari HP to deliver high performance logistics for the team’s equipment and race assets. The teams have managed the logistics for 92 Grand Prix races, covering:
• 6 kits transported simultaneously each year (kits composed of six 40-foot containers) • 52 countries crossed • More than 4,000 tons of equipment transported • More than 600,000 kilometers (375,000 miles) — roughly the distance to the moon • A fully multi-modal transport mix of ocean freight, trucking, air freight and rail transport
Premium Partner for performance, brand visibility
Moving from a Team Partner to a Premium Partner, the CEVA Logistics logo will benefit from an increased presence. CEVA is strengthening its partnership with Scuderia Ferrari HP, a team that has taken part in every edition of the Formula 1 World Championship since 1950 and holds the record for the most Grand Prix wins, with 248 victories and 16 Constructors’ World Championships. CEVA Logistics continues to strengthen its international positioning as part of its goal to become one of the world’s Top 5 logistics players. In addition to the brand exposure in the Formula 1 World Championship, CEVA Logistics will be visible as Premium Partner of Ferrari Hypercar and Ferrari Challenge.
New logistics support in 2026 for Ferrari Hypercar
CEVA will also manage Ferrari’s logistics in the Hypercar category of the FIA World Endurance Championship. The series represents the pinnacle of endurance racing performance and innovation. Ferrari has competed in this class since 2023 with the 499P, claiming numerous wins, including a historic hat-trick of victories at the 24 Hours of Le Mans (2023–2025). Ferrari Hypercar achieved a double victory in the 2025 season, winning both the Constructors’ World Championship and Drivers’ World Championship titles with car no. 51 driven by Antonio Giovinazzi, James Calado and Alessandro Pier Guidi.
Racing toward decarbonization
As part of its expertise in supporting Ferrari’s motorsports logistics, CEVA is focused on offering solutions that reduce the carbon footprint. For example, CEVA regularly takes advantage of its global warehouse network to store logistics kits instead of sending them back to Italy. CEVA also began incorporating rail transport, using it in North America in 2023 and again in 2025 to combine rail transport and ocean freight in support of the 2025 Shanghai Grand Prix (rail from Maranello to Antwerp).
Mathieu Friedberg, CEO, CEVA Logistics, said:
Since 2022, CEVA Logistics has demonstrated its commitment to pursuing the operational excellence, innovation and low carbon solutions required by a customer like Ferrari. Becoming a Premium Partner of Scuderia Ferrari HP, and now Ferrari Hypercar, is proof of CEVA’s ambition and ability to deliver excellence in support of Ferrari.
Lorenzo Giorgetti, Chief Racing Revenue Officer, Ferrari, said:
Ferrari share with CEVA Logistics a common culture built on the pursuit of excellence, innovation, and teamwork, values that drive performance both on and off the track in Formula 1 as well as in the World Endurance Championship. Over the past years, CEVA supported our racing activities around the world, combining precision and reliability with a clear vision for sustainability. As we strengthen our collaboration, we continue to push boundaries together, guided by the same pursuit of speed, efficiency, and progress that defines the Ferrari spirit.
The Jacky Perrenot Group, European transport and logistics provider, has entered into exclusive negotiations to acquire Vos Logistics, the Dutch-based logistics group. The proposed acquisition is part of Jacky Perrenot’s international development strategy and its ambition to reach €2 billion in revenue by 2027.
The completion of the transaction remains subject to customary consultation and regulatory approvals. This initiative comes just a few months after Jacky Perrenot’s acquisition of ArrowXL in June, a key step that strengthened the Group’s position in last-mile and B2C logistics across the UK. With the proposed acquisition of Vos Logistics, the Group now aims to reinforce its B2B capabilities at a European scale, while continuing to support selective B2C operations.
Strategic Move
With revenue of €1.3 billion, Jacky Perrenot has been a longstanding benchmark in transport and logistics, recognised across Europe for its operational excellence, customer focus, and leadership in fleet decarbonisation.
Vos Logistics, operating 35 branches across six European countries, generates around €400 million in turnover and is widely recognised for its expertise in international transport, multi-country distribution, and value-added contract logistics. Together, the two groups would form a pan-European operator, combining strong local networks with expanded international transport capacity.
Customer Focused
The combined organisation would represent around €1.7 billion in annual revenue, supported by over 12,000 employees across Europe. It would enhance the Group’s geographic footprint, operational performance and flexibility, and expand the range of integrated solutions available to manufacturers, retailers, healthcare providers, construction partners and e-commerce businesses.
Philippe Givone, Chairman of Jacky Perrenot Group, said: “This project is fully aligned with our growth trajectory and our ambition to build a European leader in sustainable transport and logistics. By joining forces, we can offer our clients broader coverage, higher value-added services and a responsible performance-driven model.”
Philippe Cuoc, CEO of Jacky Perrenot Group, added: “Our industry is undergoing profound transformation – operational, technological and environmental. This acquisition would accelerate our transformation and reinforce our position as a long-term, sustainable and innovative partner for clients across Europe.”
Frank Verhoeven, CEO of Vos Logistics, stated: “This partnership is a tremendous opportunity to create one of Europe’s most complementary logistics networks. We share common values with Jacky Perrenot, which will be the driving force behind this project.”
Shared Culture
Both groups have built cultures rooted in customer commitment, responsibility and operational proximity. This alignment, human, environmental and technological provides a strong foundation for a forward-looking, high-performing European logistics group.
This proposed acquisition comes at a pivotal moment for the European logistics industry, characterised by:
Growing demand for global and integrated solutions,
The need for greater supply-chain agility
Accelerating environmental and decarbonisation requirements
Intralogistics specialist TGW Logistics is investing 100 million euros in expanding its production capacity at its headquarters in Marchtrenk, Austria. This expansion of the office building at the location constitutes the next step: a five-story building will provide 14,000 m² of usable space by the second half of 2028. The investment volume amounts to 50 million euros, the groundbreaking ceremony will take place in the spring of 2026. This means that the use of the construction site already set up and equipped can continue uninterrupted – with positive effects on efficiency and economy.
“Intralogistics is an industry of the future with an average annual growth rate of roughly ten percent,” asserts Henry Puhl, Chief Executive Officer of TGW Logistics. “As an internationally leading company, TGW Logistics of course aspires to consistently apply that potential and to grow accordingly. We are striving to double our revenue by 2030 and reach over two billion euros. The investment in our headquarters in Marchtrenk lays the infrastructural foundation for that.”
Groundbreaking ceremony in the spring of 2026
The new office building will be connected to the existing building via a so-called ‘Cube’. Among other things, this will house meeting rooms, creative spaces and collaboration areas, all of which will provide the fertile soil to allow teamwork and innovation to grow. The ultramodern working environment will offer a flexible spatial concept for more than 400 employees and will be completed during the second half of 2028.
The objective of the expansion is, on the one hand, the insourcing of employees who have been working in rented external facilities up until now. On the other hand, TGW Logistics is laying the foundation for the growth planned for the coming years. The use of the construction site already set up and equipped can continue uninterrupted – with positive effects on the project’s efficiency and economy.
Affirmation of the location
“The building shells of our new production hall and the highly automated storage system were completed this past summer. The interior work is already underway, and we will put it into operation in the summer of 2026,” says Sebastian Wolf, Chief Financial Officer of TGW Logistics. “The upcoming new office building will create a 14,000 m² innovative working environment for our employees. That is a clear affirmation of the Upper Austrian location and of the growth potential of intralogistics.”
Foundation-owned company setup provides stability
Sustainable investments in long-term development are part of the corporate DNA of TGW Logistics. Its unique setup as a foundation-owned company is what makes this possible: the intralogistics specialist cannot be sold and is a stable business partner as well as a reliable employer. Two-thirds of profits stay in the company and are reinvested – in the more than 4,600 employees, in innovations and in infrastructure. The other third goes to the owner, the TGW Future Private Foundation, which in turn uses at least 30 percent of that to support the charitable projects of TGW Future Wings. Those projects focus on the comprehensive personal development of children and young people.
Loadhog, an employee-owned manufacturer of sustainable reusable packaging solutions, is proud to announce the grand opening of its new factory in Obernai, France.
Strategically located on Rue de l’Innovation, the new 5,000m² facility reflects Loadhog’s commitment to innovation, a core pillar of its operations, values, and long-term goals. This expansion marks a significant milestone in Loadhog’s journey to better serve its growing European customer base.
The Obernai factory will enable Loadhog to reduce transport costs and CO₂ emissions, enhancing sustainability for both the company and its customers. While the Hawke Street site in Sheffield will remain the central hub of the business, it will play a vital role in supporting the new French facility during its initial phase and beyond.
The first products to be moulded at the Obernai site will be from Loadhog’s intralogistics range, including its automation containers and trays. These products are designed to integrate seamlessly with automated warehousing systems, such as conveyors, robotics and transfer systems. With features like RFID compatibility, stackability, durable lightweight construction, and almost silent running, they help streamline operations, reduce manual handling, and improve throughput in high-volume environments.
Built with sustainability at its core, the Obernai factory is powered by renewable energy and proudly participates in Operation Clean Sweep®, an international initiative aimed at eliminating plastic resin loss to protect water quality, the environment, and worker safety.
Nestled in a scenic location overlooking the mountains, the new site offers an inspiring workplace for Loadhog’s team. The opening of the factory will also bring employment opportunities to the local community. By introducing specialised manufacturing and engineering skills, the facility will contribute to the area’s industrial growth and innovation landscape.
Adding to the sense of community, Loadhog’s sister company Gripple is also based in Obernai, creating a familiar and collaborative environment among like-minded businesses.
Shaun Khan, Loadhog’s Group Managing Director, commented:
Opening our new factory in Obernai is a proud moment for everyone at Loadhog. It’s a testament to our commitment to innovation, sustainability, and our people. We’re excited to bring our values to France and continue growing with our customers across Europe.
A strategic expansion in Italy’s industrial heartland aims to enhance national and international logistics services. Sogedim SpA, an independent Italian logistics operator in national and international transport, freight forwarding, and integrated logistics, announces the acquisition of Transtir S.r.l., a Modena-based company specializing in forwarding and logistics services, along with its incorporated company Fratelli Meoni SpA of Prato.
This strategic acquisition expands Sogedim’s logistics network in Italy, strengthening its presence in both Emilia-Romagna (Carpi) and Tuscany (Prato) — two regions known for their industrial districts and strong manufacturing ecosystems.
A strategic union of complementary expertise
Transtir, founded with a strong entrepreneurial vision, brings to Sogedim extensive experience in international freight forwarding, a skilled professional team, and a solid customer base across key industrial areas in central Italy. The integration enhances complementary services and boosts the Group’s competitiveness in the logistics and transport sector.
We are extremely pleased to welcome Transtir… This acquisition strengthens our presence in an economically strategic area for Made in Italy. Together, we will offer faster, more efficient, and higher-quality logistics and transport services, while maintaining the values of proximity and reliability that unite us and bind us to our customers.
Tangible benefits for customers, partners, and agents
With Transtir, Sogedim expands its distribution capacity, offering greater coverage in national and European routes together with new synergies in intermodal and logistics flows. National and international customers and partners will gain access to a broader and more integrated logistics network, optimized transit and delivery times, and an extensive range of advanced solutions. These improvements support businesses seeking efficient and scalable supply chain solutions in Italy and across Europe.
Management continuity and strong local identity
Transtir will continue to operate under its own brand, maintaining its organizational structure and management team. This ensures service continuity while allowing the company to benefit from the operational, commercial, and technological synergies of the Sogedim Group.
Modern business growth is not just about numbers… It means generating productive and logistical synergies, with full respect for the people and values that define our companies, and creating even stronger, more constructive, and long-lasting relationships.
Pack it in or monitor the noise in the warehouse, says Tim Turney, Global Marketing Manager at Casella, a global monitoring equipment manufacturer, who explains the risk of excessive noise exposure in logistics hubs and the benefits of implementing an effective noise monitoring programme.
Noise is often an overlooked operational risk in logistics, overshadowed by output, efficiency optimisations and time restraints. However, the Health & Safety Executive’s (HSE) recent investigatory campaign uncovered ‘serious gaps’ in noise safety knowledge among employers and employees in noisy workplaces. Logistics hubs are often subjected to levels over the safe prescribed limits as a result of machinery, manual handling equipment and commercial vehicles which, over a long period of time, can cause irreparable hearing loss to employees.
Too often, logistics managers will simply provide hearing protection to employees without considering the risks associated with over-attenuating PPE that can actually bring about additional risk, or considering other control measures in the hierarchy of controls.
Unmanaged noise can expose organisations to regulatory penalties, worker health claims, reputational damage, and hidden productivity losses that quietly erode margins and most importantly, leaves employees permanently suffering from partial to complete deafness. Consumer habits and market demands are creating busier logistics hubs which translates to a noisier working environment for employees.
The UK enforces management through the Control of Noise at Work Regulations 2002, which state that employers must reduce noise exposure, provide noise control measures and personal hearing protection if noise is at a level that may cause hearing loss. Employees must have personal hearing protection made available to them at an action level and must wear hearing protection at the next exposure hearing level. This assumes that the correct hearing protection wear is effectively fitted, worn at all times and maintained in good condition.
In the UK, the HSE has set an exposure limit of 85 dB(A) over an eight-hour time-weighted average, where hearing protection should be always worn, between 80 dB(A) and 85 dB(A), hearing protection is optional.
The Business Case
Chronic exposure to elevated noise levels contributes to fatigue, heightens stress, and degrades situational awareness. Elevated ambient noise can mask alarms and verbal warnings, increasing the likelihood of collision or handling incidents which in turn increases absenteeism and reduces productivity. Studies have shown that those working in loud environments are also more likely to seek alternative employment at quieter sites with turnover and sick days directly correlating to the noise levels in a worksite .
The compound result of the stress caused by excessive noise often manifests in disruptive ways. A recent survey found that a quarter of workers have ‘snapped’ at either a co-worker or manager with 20% quitting due to the noise. However it impacts employees, it is likely to cause delays in processing, transferring and day to day tasks like packaging and palletising.
The starting point for any health and safety programme is identifying the sources and quantifying the levels of hazard. By conducting a comprehensive risk assessment across the site, breaking down activities by task family and environment to understand how noise fluctuates depending on area and task, employers can deploy noise measurement and control measures cost effectively. Consider how exposure accumulates across shifts, overtime, and seasonal peaks when facilities run hotter and longer. This mapping enables targeted, defensible interventions that reduce exposure without compromising throughput or service levels.
Measurement
Sound level meters (SLMs) and noise dosimeters can be used to quantify sound levels in a workplace. Sound level meters are handheld devices, ideal for spot measurements noise at specific locations or tasks. Ideal for commissioning new equipment, diagnosing hotspots at loading docks, comparing alternative alarm types, or validating the effect of engineering controls like barrier mats or dampers.
Always calibrate before and after surveys and modern instruments will record any deviations, take notes and include information about the location, people working there, the noise environment and any control measures in place, including PPE.
Noise dosimeters serve a purpose by measuring personal exposure over a full shift. Tasks in logistics environments are by their nature mobile, so a bodily worn device may be the best way to monitor exposure. They account for worker movement, task variation, breaks, and can identify any, providing a realistic time-weighted average for specific roles such as pickers, dock associates and maintenance technicians.
To use dosimeters effectively, position the microphone in the hearing zone near the shoulder, ensuring it is unobstructed by clothing or PPE. Modern noise dosimeters are often easy to set up and can stream real-time data directly to employers’ phones or tablet so readings can be checked remotely through the day without disturbing the wearer. Repeat measurements during known peak seasons to capture worst-case scenarios that could trigger additional controls. Using both SLMs and dosimeters creates a clear picture that supports prioritisation and investment.
Control
Once the levels of sound are understood across the facility, control strategies can be implemented that follow the hierarchy of controls. At the source, employers can select low-noise wheels and tires for material handling equipment, specify quiet conveyor rollers, add soft-close pallet stops, implement variable-speed drives, and adopt other sound dampening tools to reduce total noise output.
It’s often recommended to install barriers and sound absorber around particularly noisy static machinery. Administrative controls can then minimise exposure by scheduling noisy tasks away from busy areas, creating quiet zones for precision work, and structuring maintenance windows outside of peak hours to confine noisy activities.
PPE should always be the final refuge for employers once all engineering controls and administrative controls have been considered. Hearing protection should be selected that matches the noise profile without over-attenuating as this can lead to unnecessary accidents where employees miss sound cues from vehicles or warnings from colleagues. Being struck by a moving vehicle is the second most frequent cause of workplace fatalities, according to the HSE.
Finally, conducting regular noise monitoring to calculate any changes in ambient noise levels allows employers to be agile in noise management, control and solutions. Allowing resources to be allocated when necessary, reducing overspend. At a minimum, noise surveys should be conducted every two years or whenever there are major changes to equipment, processes or working patterns. More frequent monitoring is also necessary if health surveillance reveals a decline in employee hearing quality. Where unsure, it is always recommended to consult expert advice and guidance.
Rock and roll ain’t noise pollution
Ultimately, a durable noise program depends on culture. Educating staff and managers on the dangers of long-term noise exposure and implementing a culture of responsibility will lead to better practice and caution when working in noisy environments. Logistics leaders who prioritise noise risk management create a calmer, safer, and more productive site, while also avoiding reputational and compliance penalties.
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