Beyond Zone-Based Safety: Troax Enhances Warehouse Operations with Alphasense Tracker

Warehouse managers have long relied on predefined zones and event-based systems to manage risk and control vehicle interactions—but these approaches only tell part of the story. 

To give their customers deeper operational visibility, Troax is expanding its offering with the Alphasense Tracker, bringing real-time insight into how forklifts actually move through the warehouse. 

By equipping clients with precise, location-based data on traffic patterns, interactions, and flow, Troax enables a more informed and proactive approach to improving both operational performance and risk management.

Project Details

• Number of Alphasense Tracker units: 9
• Type of vehicles tracked: Reach Forklifts & Counterbalance Forklifts
• Size of the warehouse(s): 13’000m²
• Number of sites: 1
• Fleet commissioning time: 4 hours

Visibility and safety challenges

Before exploring the Alphasense Tracker, we observed that most traditional safety systems could detect events or protect predefined zones, but they did not provide a complete understanding of how forklifts were actually moving throughout the warehouse.

Customers lacked visibility into traffic density, vehicle interactions, bottlenecks, and the precise locations where near-miss situations occurred.

Without real-time positioning data, it was difficult to proactively identify risky behaviors, optimize traffic flows, or support continuous safety improvements based on real operational patterns.

Added value

One of the most valuable aspects of the Alphasense Tracker data was the ability to transform location information into actionable safety insights through Safeyu. By combining positioning data with our existing Active Safety solutions, customers can visualize forklift movements, analyze traffic patterns, generate heatmaps, and identify high-risk interaction zones or recurring near-miss areas. This significantly strengthens our offering by moving from reactive event detection toward a more proactive and data-driven safety management approach.

Integration with Troax solutions

The integration process was very straightforward. The Alphasense Tracker could be installed directly on the vehicles without requiring heavy infrastructure inside the warehouse, which is a major advantage compared to traditional RTLS systems. The system complements very well our existing Troax Active Safety solutions, including PAS-G2, CoPilot, and Safeyu, enabling real-time data sharing and centralized visualization. Its flexible architecture also makes integration with customer systems and future analytics applications relatively simple.

Safety and efficiency gains

Real-time forklift tracking provides significant benefits both in safety and operational efficiency. From a safety perspective, customers can better understand where dangerous interactions occur, improve traffic management, define dynamic safety zones, and investigate incidents with accurate movement history. From an operational perspective, the system helps identify congestion areas, inefficient routes, unnecessary vehicle movements, and workflow bottlenecks. This creates opportunities to optimize warehouse layouts, improve driver behavior, reduce near-miss situations, and ultimately increase both productivity and overall site safety.

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“Before exploring the Alphasense Tracker, our customers were able to see safety-events linked to specific vehicles, but lacked the visibility into the specific locations where these events happened in their warehouses. While traditional systems define and protect areas, they don’t fully capture real traffic patterns or near-miss situations, making it harder to proactively address risks or optimize flow.

With the Alphasense Tracker, we now have the opportunity to add powerful location-based insights to our offering, fully capturing the real traffic patterns of our customers. Its infrastructure-free integration makes it easy to deploy alongside our existing solutions, and the real-time insights into vehicle movement open new possibilities for improving safety, traffic management, and operational efficiency for our clients. 

Combined with Safeyu, these insights become even more valuable, transforming raw positioning data into actionable analytics, heatmaps, near-miss visualization, and intelligent safety management tools for continuous improvement.”

Ricard Chetrit, Global Product Manager Active Safety, Troax

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About Troax

Troax is a global leader in safety solutions for industrial environments, offering systems that protect people, equipment, and materials by creating clearly defined and controlled zones within facilities. 

With innovations ranging from mesh panel partitions and machine guarding to automated safety barriers and driver access systems, Troax supports a safer interaction between people and material-handling vehicles. 

The company’s modular safety architecture is designed to integrate seamlessly with smart technologies, helping warehouses and production sites achieve both physical protection and operational transparency.

Through continuous R&D and collaboration with technology partners, Troax leads the way in combining physical safety with intelligent automation.“Before exploring the Alphasense Tracker, our customers were able to see safety-events linked to specific vehicles, but lacked the visibility into the specific locations where these events happened in their warehouses. While traditional systems define and protect areas, they don’t fully capture real traffic patterns or near-miss situations, making it harder to proactively address risks or optimize flow.

With the Alphasense Tracker, we now have the opportunity to add powerful location-based insights to our offering, fully capturing the real traffic patterns of our customers. Its infrastructure-free integration makes it easy to deploy alongside our existing solutions, and the real-time insights into vehicle movement open new possibilities for improving safety, traffic management, and operational efficiency for our clients. 

Combined with Safeyu, these insights become even more valuable, transforming raw positioning data into actionable analytics, heatmaps, near-miss visualization, and intelligent safety management tools for continuous improvement.”

About Alphasense Tracker

The Alphasense Tracker is a camera-based, infrastructure-free real-time locating system (RTLS) that transforms manual vehicle movement into actionable insights. 

It provides warehouses and factories with instant visibility into forklift traffic, utilization, and safety, turning raw motion data into measurable productivity KPIs.

The technology complements telematics systems by adding a data-driven layer that supports proactive risk management and continuous process improvement.

Get in touch and learn more about Alphasense Tracker.

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