Global Company | Food & Beverage
AME technologies installed in more than 10 Nestlé plants across Europe
Across several Nestlé plants, the increasing complexity of logistics flows has led to more interactions between forklifts, pedestrians and external personnel, making it necessary to further strengthen safety in material handling areas.
A particular challenge involved loading bays, where loading and unloading activities require the simultaneous presence of vehicles, operators and external truck drivers. The objective was therefore to protect people in the highest-risk areas while ensuring the continuity and efficiency of logistics operations.
Across several Nestlé plants, AME developed flexible solutions to enhance safety during loading and unloading operations without compromising operational continuity. Depending on each plant’s specific needs, layout and traffic flows, the protection of external personnel was addressed through different safety technologies and configurations.
Smart Mat – Operator with TAG:
the smart mat defines the SAFE AREA; when the TAG-equipped driver reaches the SAFE AREA, the TAG is inhibited and forklifts operate normally. If the driver leaves the area, the TAG is reactivated and forklifts slow down when the TAG is detected.
Smart Mat – Operator without TAG:
forklifts automatically reduce their speed when the driver is outside the SAFE AREA and return to normal speed operation when the operator is detected on the mat.
TAG + Light signalling:
when the truck enters the loading bay, a light signal is activated and is switched off when the TAG-equipped driver reaches the SAFE AREA.
AI Camera Detection:
the presence of operators is detected by AI cameras when the truck is in the loading bay. When an operator is detected, the AME sensors are activated and vehicles in the area automatically slow down.
In addition to manually operated forklifts, AMESPHERE collision avoidance technology has also been integrated with Automated Guided Vehicles (AGVs) across several Nestlé plants. The system detects the presence of TAG-equipped personnel in real time and automatically adjusts the vehicle’s speed when approaching a person.
To further strengthen safety management, several Nestlé plants have integrated AMESPHERE software services, which leverage data collected by field sensors to provide deeper insight into operational dynamics, both from a safety and efficiency perspective. This enables teams to monitor safety conditions, identify recurring patterns and guide improvement actions based on objective data.
The adoption of AMESPHERE solutions has enabled Nestlé to strengthen safety across loading bays and material handling areas, with configurations tailored to the specific requirements of each plant.
The ability to combine different technologies and intervention methods has allowed Nestlé to standardize its approach to safety while maintaining the flexibility required by each plant, without compromising operational continuity.
Reduced risk of interaction between people, forklifts and AGVs
Enhanced protection in loading, unloading and material handling areas
Operational continuity and performance without unnecessary slowdowns
Continuous monitoring of safety conditions through objective data
