Operating forklifts safely in cold storage facilities

Cold storage environments pose unique challenges to safety, especially when it comes to operating forklifts. The combination of low temperatures, limited visibility due to condensation, and the risk of ice can lead to hazardous conditions. In this article, we’ll explore the best practices for ensuring forklift safety in cold storage facilities, focusing on the specific challenges these environments present.

Understanding the challenges of cold storage

Cold storage facilities are typically maintained at temperatures ranging from -18°C (0°F) to -40°C (-40°F), as opposed to chiller rooms that are a balmy 2°C (35°F), give or take. Operating forklifts in such environments demands extra caution and preparation due to the following factors:

1. Low temperatures: Cold temperatures can affect the mechanical components of forklifts, and the operators. Forklift batteries may have reduced performance, and hydraulic fluids can become more viscous, leading to slower response times. Cold stress on operators can lead to fatigue and decreased concentration, loss of dexterity in the hands due to cold and having to wear thermal gloves, and tension in the shoulders due to hunching when cold.
2. Ice and slippery surfaces: When forklifts exit the coolstore into the regular ambient environment, humid air is let in. Even a small amount of moisture can freeze, creating slippery conditions that increase the risk of forklifts sliding or skidding when turning or braking (something that can be variable, depending on the forklift’s load). Ice buildup can also form on forklift components, such as tyres and brakes, reducing their effectiveness.
3. Reduced visibility: Condensation and frost on forklift mirrors and the operator’s glasses can impair visibility, making it harder for operators to navigate safely. The dim lighting typical of many cold storage facilities can exacerbate this issue.
4. Tight spaces: Cold storage facilities often have narrow aisles and tight spaces, which can be challenging to navigate with a forklift. The risk of collisions with racks, walls, or other equipment is higher in these confined environments.

Best practices for forklift safety in cold storage facilities

You can mitigate the risks associated with operating forklifts in cold storage environments by implementing targeted safety practices, such as the following:

Use forklifts designed for cold environments

Not all forklifts are suitable for cold storage. It’s important to choose forklifts that are specifically designed or modified to operate in low-temperature environments. These forklifts can feature:

• Cold-resistant materials: Forklifts designed for cold storage may use materials that resist brittleness at low temperatures, or resist rust, such as galvanized metals, shielded drive motors, etc
• Sealed cabins: some forklifts have a cabin with a heater and a defroster; some walkie stackers have a heated handle.
• Anti-slip tyres: Special tyres with improved friction can help reduce the risk of skidding on icy surfaces.

Regular maintenance and inspection

Key areas to focus on include:

• Battery care: You will most likely be using batteries because a cold storage facility is not ventilated for petrol, diesel or LPG, and hydrogen creates too much water vapour. Cold temperatures can drain batteries quickly; ensure that batteries are fully charged before each shift and consider using batteries designed for low temperatures.
• Hydraulic systems: Check hydraulic fluids regularly, as they can thicken in cold environments, leading to sluggish performance. Using low-temperature hydraulic fluids can help maintain performance.
• Tyres and brakes: Inspect tyres for adequate tread and check brakes for responsiveness. As mentioned previously, ice buildup on these components can lead to dangerous situations, particularly understeer in corners.

Training and certification for operators

Proper training is essential for all forklift operators, but it’s especially important in cold storage environments. As well as having a forklift licence, operators should be trained on:

• Cold environment hazards: Understanding the specific risks associated with operating forklifts in cold temperatures both on the forklift and on their body and mind.
• Emergency procedures: Knowing how to respond to emergencies, such as a forklift sliding on ice or an operator experiencing cold stress.
• Defensive driving: Emphasising cautious driving, including reduced speeds, maintaining safe distances from other equipment and workers, and understanding whether there are practical limits on the maximum load that can be carried due to the slippery situation.

Enhancing visibility

Visibility is a significant concern in cold storage facilities.

• Heated windows: If possible, use forklifts with heated vents that can blow on the inside of the windows to prevent fogging and frost buildup.
• Lighting: Ensure that the facility is well-lit. LED lights are a good choice for cold environments as they perform well in low temperatures.
• Mirrors and cameras: Install additional mirrors or cameras on forklifts to provide better views of blind spots, especially in tight spaces.

Implementing safe operation practices

As we mentioned above, defensive driving is crucial to prevent accidents in cold storage facilities. Operators should adhere to the following guidelines:

• Reduce speed: Slower speeds allow for better control of the forklift, especially on slippery surfaces where understeer is likely.
• Avoid jerky movements: Gradual acceleration, braking, and turning reduce the risk of skidding.
• Maintain safe distances: Keep a safe distance from other forklifts, racks, and workers to allow for unexpected stops or movements.

Addressing operator comfort and safety

Cold stress can impair an operator’s ability to concentrate and react quickly. To ensure operator safety and comfort:

• Provide appropriate clothing: Operators should wear insulated clothing, gloves, and footwear designed for cold environments, but also understand that bulky clothing makes it harder to operate the forklift. Clothing should allow for freedom of movement while providing adequate warmth.
• Schedule breaks: Regular breaks in a warm environment can help prevent cold stress and maintain operator alertness. Provide a place where operators can heat food, and get hot drinks such as tea and coffee.
• Heated cabins: If possible, use forklifts with heated cabins to provide a more comfortable working environment.

Creating a safe work environment

Beyond the forklift itself, the environment plays a crucial role in safety. Consider the following:

• Floor maintenance: Regularly clear floors of ice and snow. Use salt or sand to improve traction in high-traffic areas. Fix potholes and cracks.
• Clear markings: Ensure that floor markings and signs are visible and clear, even in low temperatures.
• Emergency equipment: Keep emergency equipment, such as first aid kits and thermal blankets, readily available in case of an accident.

Operating forklifts in cold storage facilities presents some unique challenges. By using forklifts designed for cold environments, conducting regular maintenance, providing proper training, and implementing safe driving practices, the risks can be significantly reduced.