Forklift Pedestrian Detection Systems: 2025 Guide

How EHS Managers Can Evaluate AI, RFID, and Hybrid Solutions for Safer Facilities

Introduction

Forklift–pedestrian interactions are one of the biggest blind spots in today’s safety culture—literally and figuratively. As industrial facilities become denser and more dynamic, the need for reliable, automated pedestrian detection systems has become a frontline priority for EHS and safety leaders.

I’ve seen firsthand how these systems, when properly chosen and implemented, can prevent close calls from becoming catastrophes. This guide is built from field experience, not theory—and it’s designed to help you cut through the noise and choose what actually works in your facility.

“When you walk a site that just had a near-miss, the conversation shifts fast. Suddenly, it’s not about cost or features—it’s about what could’ve happened. That’s where smart safety systems earn their place.”— John Buttery.

Author's Perspective

Forklift safety is personal. I’ve had conversations with operators who’ve barely missed someone walking behind a rack. I’ve seen the fatigue in a safety manager’s eyes after yet another “lucky break.” This is not about fancy dashboards or AI hype—this is about protecting lives with technology that doesn’t flinch, blink, or take a coffee break.

You don’t need complexity—you need clarity, speed, and consistency. And in 2025, the tools to make that happen are ready.

Relevance

Why does this matter now? Because the modern warehouse, plant, or construction site has evolved:

• 🛻 Quieter electric forklifts

• 🏗️ Increased throughput and foot traffic

• 🧍‍♂️ Temporary labor and less training

• ⚠️ More blind spots, narrower aisles, and fast shifts

• 
  

Safety practices from five years ago no longer cut it. Detection systems must become part of daily operations, not just a box to check during audits.

Technology 1: AI Camera-Based Pedestrian Detection

“Tag-free detection powered by vision and intelligence.”

AI-based systems use cameras and algorithms to detect pedestrians without requiring any wearable tags or Wi-Fi infrastructure. They analyze movement and form in real time, alerting operators to human presence—not just objects or motion.

🔹 Best For:

• Dynamic workforces (contractors, temps, delivery staff)

• High-risk intersections or blind corners

• Facilities with poor tag compliance

🔍 Key Benefits:

• No tags or infrastructure required

• Real-time human recognition (not motion-based)

• Works in day/night conditions

• Scalable across fleets without heavy IT

⚠️ Evaluation Factors:

• Light/dark performance (sun glare, shadows)

• False positives vs. false negatives

• Alert clarity and operator response

• Blind spot and intersection coverage

• Installation and scaling speed

“AI safety cameras don’t just see people—they learn from patterns, lighting, and blind spots. They do something your best-trained operator can’t: detect risk before it becomes an accident.”— John Buttery.

Technology 2: RFID or UWB Proximity Detection

“Zone-based safety with wearable certainty.”

These systems use Ultra-Wideband (UWB) or RFID tags to detect proximity between forklifts and pedestrians. If someone wearing a tag enters a danger zone, an alert is triggered for both the operator and the pedestrian.

🔹 Best For:

• Controlled-access environments

• Long-term employees with high tag compliance

• Standardized workflows and safety zones

🔍 Key Benefits:

• Highly accurate distance and zone detection

• Low false positive rate

• Works well in noisy or visual-obstruction areas

• Integrates with doors, lights, or floor markings

⚠️ Challenges:

• Tags must be worn 100% of the time

• Batteries must be charged and maintained

• Infrastructure setup can be complex

• Less effective for untagged visitors or contractors

“RFID and UWB systems perform extremely well when the environment is right. The key is ensuring tag compliance so every pedestrian stays protected consistently.” — John Buttery

Technology 3: Hybrid Detection Systems

“The smartest facilities combine both worlds.”

Hybrid systems fuse AI visual detection with RFID or UWB tag-based logic, offering dual-layer protection. These systems detect both tagged and untagged pedestrians, often customizing alerts by role, zone, or time of day.

🔹 Best For:

• Manufacturing campuses with multiple zones

• Warehouses with heavy contractor or visitor traffic

• Organizations seeking advanced analytics

🔍 Key Benefits:

• Works with both tagged and untagged personnel

• Supports smarter automation and integration

• Future-proofs safety investments

• Delivers analytics and tracking by role or user

⚠️ Things to Consider:

• More expensive and complex to implement

• May require deeper integration with other systems

• Needs clear workflow mapping

The One-Unit Evaluation Method

“Start small. Prove real.”

Before scaling a system across your site, run a real-world, single-unit trial.

• Install on 1 forklift

• Test in real operating conditions

• Evaluate with actual staff and loads

• Collect feedback within 2–3 weeks

This low-risk trial gives you operational data, shows gaps, and helps win buy-in from skeptical teams. It's far better than a months-long pilot that ends in analysis paralysis.

Actions You Can Take Today

1. Walk Your Risk Zones

   Map out where pedestrian-forklift interaction is highest. Blind corners, crosswalks, staging zones—start there.

   
   

2. Decide on Tag Strategy

   Can you enforce 100% tag compliance? If not, lean toward AI or hybrid systems.

   
   

3. Run a Field Test on One Forklift

   Gather insights from real usage, not just vendor demos.

   
   

4. Talk to Operators First

   If they hate the system, it won’t succeed. Engage them early.

Conclusion

There’s no perfect safety system—but there is a right one for your people, layout, and risk profile. AI, RFID/UWB, and hybrid technologies each have their place. The right decision is the one that gets used, reduces risk, and doesn’t disrupt productivity.

Think simple, act fast, and build confidence from the ground up.

Call-To-Action

If you're unsure which system fits your environment—or need an honest opinion—I’m happy to help. I work with EHS and Ops teams to cut through the noise, identify the right fit, and deploy systems that work. Reach out directly or connect below.

About the Author

John Buttery — Forklift Pedestrian Detection, AI Safety Technology & EHS Solutions

CEO, Riodatos | Safety Strategist | Author | Industrial Solutions Leader

With more than 30 years of experience in industrial technology, I help EHS, Operations, and Safety leaders choose, implement, and scale modern forklift pedestrian detection systems. Through Riodatos, I support manufacturing, logistics, and warehousing facilities in reducing risk with practical, field-tested safety tech.

🔧 What I Do:

• Help teams choose the right detection system (AI, RFID, hybrid)

• Deliver real-world deployment advice

• Remove vendor confusion and friction

• Enable scalable site-wide rollouts

• Support zero-incident safety cultures

🛠️ Areas of Expertise:

• Forklift pedestrian detection (AI, UWB, RFID, hybrid)

• Collision avoidance & operator assist systems

• EHS technology: audits, analytics, telematics, compliance

• GNSS, GIS, machine control, autonomous sensors

• Channel and dealer development across the Americas

• 
  

📧 jwbuttery@gmail.com🔗 LinkedIn🔗 Twitter/X🌐 www.riodatos.com

Social Media Links:

💭 Share your thoughts🔷 Please like, repost, and share✅ link: Connect on LinkedIn☑️ link: Follow me on Twitter📧 Email me at jwbuttery@gmail.com

Summary - Forklift Pedestrian Detection Systems: 2025 Guide

Forklift–pedestrian collisions are still one of the biggest safety challenges in industrial environments. In this 2025 guide, I break down what every EHS Manager needs to know to evaluate today’s top safety technologies.

🔍 Key Takeaways:

• 🤖 AI camera systems (no tags, instant alerts)

• 📡 RFID/UWB proximity systems (precise but tag-reliant)

• 🔄 Hybrid systems (ultimate flexibility)

• ✅ The One-Forklift Evaluation Method

• 📋 4 simple actions to take this week

• 
  

Make smart moves. Prevent the preventable.

---

#ForkliftSafety #EHS #PedestrianDetection #RFID #WarehouseSafety #IndustrialSafety #ConstructionSafety #SafetyTech #LogisticsSafety #AI