FORKLIFT TRUCKS O
ne area of particular focus should be the loading area, which remains one of the most dangerous. Within the loading area, some practices involve more risks than others. Containers are, and will
continue to be, a cornerstone of the logistics supply chain. Their versatility, being able to transport them by land, sea or air, makes them perfect for shipping a whole array of goods. However, to load and unload them takes a great deal of care and skill. This is because container loading presents
unique challenges, particularly when forklifts are required to enter the container. In this case, operators must deal with restricted access points, tight operating spaces and limited visibility and room for manoeuvre when compared with navigating other warehouse spaces that are usually much wider. Invariably, this places extra demand on forklift operators and equipment, and leaves little margin for error. So, how does a business reduce risk from
its container loading process without slowing the entire operation down? The answer isn’t by removing forklift trucks from the operation altogether, but rather by rethinking where they are used and if they remain the best option. Considering where automation can have the biggest impact, such as by using solutions like automated loading systems, and constantly revisiting other operational processes within the container loading workflow, can help businesses reduce risks and improve efficiency, while finding new ways to contribute towards productivity and profit targets.
WHAT’S THE PLAN? Safer container loading starts by re- evaluating the container handling workflow. While every facility operates differently, there are many steps businesses can take to assess and improve their own operational setup. For example, a loading plan should map
where loads are stored, as well as the forklift and pedestrian movements involved in transporting and loading them into the container. It should map out what will go into the container, where it will go and in which order, helping logistics teams maximise space and distribute weight evenly. Poorly positioned or unstable loads can increase the need for corrective manoeuvres during loading, which requires additional forklift movements and thus increases the operator's exposure to risk. A strong plan, therefore, not only communicates what to load, but how to do so in a way that reduces the number of times a forklift is used and for how long. It’s part of a wider conversation shift from
simply what gets done to how it gets done. Equipment and technology are already a fundamental part of the workflow, but the question now is how they can be used to further streamline operations and reduce unnecessary handling. Just having the technology or equipment isn’t enough; businesses also need to keep reviewing how it is used. For example, is there a way
BEST PRACTICES FOR SAFER CONTAINER LOADING AND UNLOADING
By Wouter Satijn, Chief Revenue Officer, Joloda Hydraroll
Earlier this month was National Forklift Safety Day, an important reminder for businesses to review how they keep forklift safety front of mind in the drive to increase efficiency and productivity in the supply chain operation
to minimise repeated forklift movements in the loading area or remove them from inside the container altogether? This would not only improve safety but also create more controlled, predictable environments to increase throughput.
REPETITIVE STRAIN Forklift safety is often discussed in terms of equipment, training and operational procedures, yet the person behind the controls remains one of the most important factors in maintaining a safe container loading environment. Container loading can be physically and mentally demanding on operators, especially when loading schedules are intensive and activities are highly repetitive. Repeatedly manoeuvring forklifts into
and around containers throughout a shift, combined with long operating periods and production pressures, can all contribute to mental fatigue. This can lead to a reduction in alertness, meaning slower reaction times and lapses in concentration, all of which can
20 JUNE 2026 | FACTORY&HANDLINGSOLUTIONS
have serious consequences when operating a forklift within containers or loading areas in close proximity to other personnel. The physical demands of manual container
handling can further compound this issue. The repeated lifting, bending and twisting involved can take its toll and contribute to musculoskeletal strain. When these factors combine, the potential for mistakes, near misses and other forklift-related incidents can increase, reinforcing the need to re- evaluate workflows and find new ways to reduce manual handling and, therefore, operator exposure to unnecessary risks.
STANDARDISED SEQUENCES Standardisation is one of the most effective ways of maintaining safe forklift operations during container loading. While operators are trained to adapt to different situations and follow prescribed workflows, reliance on manual processes and forklift trucks will inevitably lead to variability in the working environment. Disparities in loading methods, cargo positioning and traffic flow can all
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