How training, equipment, and the latest tech can help protect workers and products

As material handling operations become more technologically advanced and complex, safety measures are evolving to match.

From training and planning to equipment selection, warehouse safety demands precision.

Safety and training opportunities through e-learning

Russ Hennigar is working in the field through education.

A former educator, Hennigar has created a training program that MHEDA has used for the past five years. He has recently adapted a version of the course for Material Handling Wholesaler in the Material Handling Bootcamp safety courses.

“Basically, the course is to teach fundamentals in the business that would otherwise take months or years to learn,” Hennigar said.

Hennigar’s career track went from education to sales at McGraw-Hill to following a family member into the material handling field.

He started as a full-line distributor salesman at a large material handling company, eventually becoming vice president and general manager and a member of the distributorship’s board of directors, according to Hennigar’s online biography.

“I ended up in a career in material handling, totally alien from my background,” he said, of the career switch.

In his new career field, Hennigar quickly realized the need for reference texts, training, and education opportunities.

“This is what the purpose is. That’s why I developed the courses,” he said, noting that after some time and tweaking, the courses are now steadily in demand.

Courses include topics like: “Drive in Rack, Pallet Flow Rack, Shelving Basics, Truck and Dock Basics, and more,” according to the website.

The classes are designed with “micro-content,” or small collections of information that can be easily learned and retained, according to the website.

“Sudden Impact: Material Handling Fundamentals” is a course designed specifically for those new to the industry.

“People who have been around for a while are juggling quotes, customer calls, warehouse walks, and constant pressure for faster turnaround. There’s rarely time to teach,” a preview of the course said.

In an industry with a broad array of products, equipment, and even buildings, the learning curve can be steep, according to the course description.

So, training needs to start with the fundamentals, according to Hennigar.

He draws on his experience as a distributorship owner and as a vice president and industrial salesperson at a rack and shelving manufacturing company to create his training course material.

His knowledge of the industry is “practical and multifaceted,” according to his biography.

“I guess it’s the old teacher in me. I thought of this 10 years ago, and the technology wasn’t there. The learning platforms weren’t there. E-learning wasn’t available. Then it started getting popular,” he said.

Hennigar said the first steps in developing the videos for the classes were lengthy, but now that they are established, tweaking the coursework with AI is a simple process.

“The technology is just so wonderful,” he said.

For more information about the courses, visit materialhandlingbootcamp.com

Tech solutions for emergencies

Some companies, such as Silent Beacon, are developing products to help establish a safe working environment.

Silent Beacon is a wearable panic button designed to help workers call for help during emergencies, according to the business.

The Silent Beacon technology enables workers to call for help during emergencies, share real-time GPS location, and enable two-way communication, according to the company.

The technology can be used in a variety of settings, including businesses and by individuals.

Tyler Charuhas, director of client engagement, often helps Silent Beacon clients looking to protect their employees with the technology.

He said that about six years ago, the company’s leaders observed the need for companies to address safety gaps.

“We were looking at website orders and a lot of those ordering our product were businesses,” Charuhas said.

The company’s range of clients is wide – everything from full hospital systems to small offices to individual use – and many users are in the material handling realm.

Charuhas estimated that one in 10 recent inquiries about the technology concerns protecting warehouse workers.

According to Charuhas, Silent Beacon developed a platform specifically for this need.

He said many warehouse operations want to be proactive about security, with solutions that notify many people of incidents simultaneously, provide two-way communication, and let them call with a single button press.

“Our device definitely fills that gap,” Charuhas said.

The technology can be tweaked for each specific operation, from smaller operations to multi-shift and large businesses.

Silent Beacon’s “Enterprise Safety Solutions” bundle offers businesses a comprehensive suite of wearable panic buttons, a safety app, a cloud-based dashboard, and a mass alert portal, according to the company.

Silent Beacon offers examples of the technology in action on its website, detailing how it has aided in compromised situations as well as general safety calls.

The key to the technology is eliminating any middle step in a safety call, according to Charuhas.

“A lot of other devices on the market, when you press or engage, it’s calling a call center or triggering them to call you. With our device, we have the ability to call 911 directly,” he said, noting that Silent Beacon has a microphone and speaker allowing a user to talk to the device directly.

Some companies have on-site security staff, so Silent Beacon can adapt the technology to call internally as well.

“You get to choose who it calls,” Charuhas said.

And the technology’s implementation is simple, according to Charuhas.

“It’s Bluetooth-connected, so it piggybacks off users’ smartphones or tablets. The integration is very simple,” he said, adding that Silent Beacon typically has new clients up and running within less than a week.

Silent Beacon is developing a non-cellular version of the technology and making ongoing technological improvements, Charuhas said.

“Our main goal is to continually update new hardware,” he said.

Others are offering visual and signaling safety solutions.

Pfannenberg, Inc., a global company in thermal management and signaling technologies, will showcase its fire alarm signaling solutions at the June 2026 NFPA Conference & Expo in Las Vegas, according to a press release.

“As industrial environments become louder and more complex, the need for clear, code-compliant alarm coverage continues to grow,” said Jacob Vernon, product manager for Audible and Visual Signaling at Pfannenberg, in the statement.

He said the company’s PATROL, PYRA, and PROTECT product lines offer fire alarm systems for harsh industrial settings, according to the statement.

At the conference, Pfannenberg will highlight three signaling solutions, according to the statement. The PATROL line of audible and combination devices is designed for adverse conditions such as high ambient noise levels and bright surroundings.

The PYRA line offers visual signaling for industrial notification, including strong visibility and flexible installation options.

And the PROTECT series includes “audible and combination devices for demanding industrial, hazardous, and explosive environments,” the statement said.

“From mild industrial spaces to the most extreme and hazardous environments, Pfannenberg offers the tools, products, and knowledge to help customers safely construct an optimal fire alarming system,” the statement said.

About the Columnist:

Eileen Mozinski Schmidt is a writer and journalist based in the Greater Milwaukee area.  If your company would like to be featured, email [email protected]