Amcor Flexibles - A Full Pedestrian Walkway Upgrade

Amcor Winterbourne's Challenges

With 15 forklifts and up to 400 pallet movements per day, the Winterbourne site faced risks around workplace transport. Pedestrians and FLTs were often working in close proximity, creating the potential for incidents.

The business wanted a robust workplace transport plan to bring their site in line with new internal EHS requirements. A particular challenge came from updated internal legislation requiring staff to remain at least three metres away from forklifts — even though some of the equipment on site were hand trucks, not traditional FLTs.

Amcor needed a complete solution that would both meet central EHS standards and keep the shop floor running smoothly.

LED Projected Zebra Crossing in UK Warehouse

Amcor 3D Visuals - Safety Barrier Layout

Floor Coating at UK Warehouse - Safety Plan

The Solution:

Clarity Safety worked closely with Amcor’s team to design and install a pedestrian segregation system that balanced compliance with practicality.

We supplied:

Polymer pedestrian barriers to keep staff separated from forklift routes
Gates and crossings to control access at key points
Floor painting and LED Projectors to reinforce safe pedestrian routes and crossings

The system was designed to be modular, so if further requirements are introduced following EHS reviews, additional barriers can be easily added without disruption.

The Result:

The project was described as a great success, with the safety improvements generating significant interest across the wider Amcor group. The Winterbourne site was selected as an example of best practice and featured in an internal presentation showcasing the solutions that had been implemented. The presentation received very positive feedback, with colleagues from other Amcor locations expressing interest in the project.

As a result, representatives from other Amcor sites arranged to visit the Winterbourne facility to see the installation first-hand, demonstrating the impact and visibility of the project across the organisation. The site contact, also confirmed that he would happily recommend Clarity Safety to other Amcor sites looking to improve workplace safety and visual management.

The project not only improved safety awareness on site, but also provided a benchmark for other facilities within the Amcor network to follow.