Cold Storage.
Reliable detection in punishing conditions, the same demand offshore made of the technology.
Cold stores combine constant forklift traffic, icy floors and demanding conditions for both people and cameras. SecureSafety keeps watching where supervision is hardest.
Why this sector is demanding.
Cold storage and temperature-controlled distribution facilities present a unique combination of hazards. Constant forklift traffic moves through narrow aisles at low visibility, workers operate in conditions that reduce manual dexterity and cognitive performance, and icy or wet floors create slip risk that is orders of magnitude higher than a normal warehouse environment. Supervisory rounds in a busy freezer store are brief and uncomfortable, creating extended periods where workers in remote aisles and staging areas are effectively unmonitored.
Camera performance in cold and low-light environments is a practical challenge that most general AI safety platforms have not been tested for. Condensation on camera lenses, infrared reflection from highly reflective racking systems and reduced contrast in low-temperature lighting all affect detection accuracy. SecureSafety has operational experience in environments that demand reliable detection under adverse conditions — the same reliability standard the offshore environment established — and confirms camera performance before go-live.
Lone-worker risk is elevated in cold storage because workers in remote areas of large freezer stores may be concealed behind high racking with no line of sight to colleagues or supervisors. A fall, a medical event or a period of incapacitation may not be noticed before the situation becomes serious. Camera monitoring combined with wearable check-in and man-down detection provides the continuous thread on every worker that manual supervision cannot.
The problems AI solves here.
Forklift-pedestrian conflict in narrow, high-racking aisles
Cold store aisles are typically narrower than standard warehouse aisles and use high racking that restricts sightlines at aisle ends. SecureSafety monitors every aisle end and intersection, alerting when a forklift and pedestrian are on a convergence course before contact. Vehicle speed is tracked simultaneously to surface repeat offenders.
Slip and fall detection on icy and wet surfaces
Icy and condensation-wet floors in cold stores and transition zones generate a slip hazard that is significantly higher than a normal warehouse. SecureSafety monitors for person-on-ground events across all camera zones, flagging falls within seconds and routing alerts to the first-aider and supervisor on shift.
Lone-worker monitoring in remote freezer areas
Workers in remote sections of large freezer stores may be beyond camera coverage or out of sightline for extended periods. The platform integrates wearable BLE check-in devices and man-down sensors to maintain a continuous thread on every lone worker, generating an alert if a check-in is missed or a no-motion event is detected.
Cold-environment reliability was a core requirement of the offshore deployment, where cameras operate in extreme weather conditions and must maintain detection accuracy through spray, temperature variation and vibration. The same engineering standard that qualifies the platform for offshore deployment makes it reliable in a freezer store.
Questions from cold storage.
How does the system handle condensation on camera lenses inside cold stores?
Camera positioning and housing are reviewed during the Discovery phase to minimise condensation. Where condensation is unavoidable, heated camera housings or positioning adjustments are recommended. Detection thresholds are configured to account for the actual camera conditions in your facility.
Does the system work in very low light — some freezer areas are dark when unoccupied?
Yes. The platform integrates with infrared camera feeds and operates across the lighting conditions typical of cold store environments. Motion-triggered lighting in unoccupied aisles can also trigger camera activation, which is supported in the zone configuration.
Can the system cover the areas between temperature zones — transition airlocks and staging areas?
Yes. Transition zones and airlocks are often the highest-traffic areas in a cold store facility and are standard camera coverage locations. These areas carry forklift-pedestrian and slip risk, and zone rules can be configured to reflect the specific hazard profile of each transition point.
How does the lone-worker wearable work when a worker is deep inside a freezer store beyond WiFi range?
The wearable system uses BLE beacons rather than WiFi for indoor location and check-in. Beacons are placed throughout the store to provide continuous coverage. Where beacon placement is not possible in all areas, the wearable man-down sensor operates independently of network connectivity and stores events for transmission when the worker returns to coverage.
Can cameras work reliably in a blast freezer at -30°C?
Yes. Cameras specified for cold storage deployment use heated housings that maintain the camera electronics and lens at operating temperature regardless of the ambient conditions. The Discovery phase identifies the temperature range and humidity conditions in each monitored area and specifies the appropriate housing. Detection accuracy in cold store environments is confirmed during commissioning before go-live.
How does lone-worker monitoring work for workers inside a cold store without camera coverage?
Where camera coverage does not extend to all areas within a cold store, wearable safety smartwatches provide the man-down and no-motion detection that covers the unmonitored areas. Check-in intervals for cold store lone working are typically shorter than for ambient environments — 5–10 minutes rather than 15–30 — reflecting the faster physiological deterioration in cold environments. The check-in and man-down alerts are unified with camera alerts on the same site map.
How do you handle the condensation that forms when a cold store door is opened frequently?
Condensation at cold store door entries is managed by a combination of heated camera housings and camera placement that avoids the primary condensation zone immediately inside the door. Where the entry point is the primary monitoring location, cameras are positioned above the condensation band with a downward angle that provides adequate coverage of workers entering the zone. Detection performance through moderate condensation is confirmed during commissioning; the Discovery phase camera survey identifies the specific conditions at each entry point.
What are the specific regulatory requirements for lone worker monitoring in cold stores?
The UK Workplace (Health, Safety and Welfare) Regulations 1992 require appropriate temperature conditions for workplace activity, and the HSE guidance on lone working sets out the obligation to identify lone working risks and implement appropriate monitoring and communication arrangements. For cold stores specifically, the low ambient temperature accelerates the physiological deterioration that follows a medical emergency or fall, which means the discovery time requirement is shorter than for ambient environments. A check-in interval of 5-10 minutes is typically appropriate for cold store lone working, with the first escalation to a supervisor response within the subsequent 5 minutes.
Can the wearable monitoring be integrated with the cold store door management system?
Integration between wearable monitoring and cold store door management systems is available via API where the door management system provides accessible data. The most useful integration is one where the door management system can confirm that a registered worker has exited the cold store, closing out the lone-worker monitoring session automatically. Where this integration is not available, manual check-out from the wearable device or a secondary camera at the exit point provides the equivalent session closure. The Discovery phase assesses the door management system in use and the feasibility of integration.
Tell us the hazard. We'll detect it.
Book a demo and we'll show SecureSafety running in a cold storage environment. Then scope your site with a fully-costed Discovery phase.