Stop Near Misses in Their Tracks: Why Mag Lock Barrier Systems Are a Game-Changer for Warehouse Safety
Protecting People on the Move
In a busy warehouse, the line between safe operations and serious accidents is razor thin. One distracted pedestrian or an unseen forklift can change everything in a heartbeat. That’s where Mag Lock Barrier Systems come in. An intuitive, tech-powered safety solution designed to prevent near misses before they happen.
At Ulti Group, we’ve seen firsthand how these systems have transformed safety standards across warehouses throughout New Zealand. In this blog, we’ll explain what a Mag Lock Barrier System is, how they work, and why they’re quickly becoming an essential part of smart warehouse safety systems.
What is a Mag Lock Barrier System – and Why Does it Matter?
Mag Lock Barrier Systems are industrial access control systems that use electromagnetic locking mechanisms to control and restrict pedestrian movement in hazardous warehouse areas – especially where forklifts and people operate in the same zones.
Traditional warehouse safety measures often rely on floor markings or signs, which can be ignored or overlooked. A Mag Lock Barrier System can take things further by actively blocking pedestrian access when it’s unsafe to proceed and allowing free movement only when the area is clear.
For warehouses that deal with high volumes of traffic or have recorded frequent near misses, this system becomes a vital piece of the safety puzzle.
How Does a Mag Lock Barrier System Work? A Smart, Multi-Layered Approach to Safety
As Rhys Clareburt, one of our sales consultants, explains in the video above, the Mag Lock Barrier System is designed to be intelligent, responsive, and easy to use:
“This is a great solution if you’re wanting to separate forklifts or trucks from your pedestrians on the warehouse floor.”
Here’s a breakdown of how the system works:
1. Vehicle Detection via Sensors
The system uses either:
- Ground-based sensors positioned to detect oncoming traffic, or
- Overhead AI-powered sensors mounted on the ceiling that track vehicle movement from above.
2. Visual Alerts for Pedestrians
Once a vehicle is detected, a visual cue is triggered:
- A projected image or floor light changes to indicate danger.
- A traffic light system switches from green to red.
3. Access Control via Magnetic Locking
- Green Light = Safe. The gate unlocks, and pedestrians can walk through freely.
- Red Light = Stop. The magnetic lock engages, and the gate cannot be opened until the danger has passed.
“When the light is red, it means there’s either a forklift, truck, or vehicle about to approach, and the pedestrian will be unable to open the gate.”
This simple but powerful system eliminates human error by removing the option to make unsafe decisions.
Benefits That Go Beyond Safety
✅ Fewer Near Misses and Incidents
This is the biggest win. By physically preventing unsafe access, the Mag Lock Barrier System reduces the potential for pedestrian-vehicle collisions – protecting both people and productivity
✅ Meets Health & Safety Compliance
Mag Lock Barrier Systems help meet and exceed WorkSafe NZ and ISO safety standards, providing peace of mind for operations managers and safety officers alike.
✅ Boosts Worker Confidence
Your people notice when you invest in their safety. A safer environment means improved morale, stronger engagement, and a better workplace culture overall.
✅ Customisable to Any Warehouse
No two warehouses are alike. That’s why our Mag Lock Barrier solutions are fully customisable. We tailor sensor types, locations, and locking mechanisms to suit your layout, traffic flow, and operational demands.
✅ Integrates with Existing Safety Systems
Already using barriers, bollards, or walkways? Mag Lock Barrier Systems can easily be integrated into your existing safety ecosystem, adding a smart layer of automation and control.
Who Should Consider Mag Lock Barrier Systems?
If you’re operating in a warehouse environment where:
- Pedestrians and forklifts frequently share the same space,
- There’s been a recent rise in near miss incidents,
- You rely heavily on visual-only safety tools (like floor tape or signage), or
- You’re under pressure to improve your health and safety performance,
… then it’s time to consider installing a Mag Lock Barrier System.
These systems are particularly valuable in:
- Logistics and distribution centres
- Cold storage and food processing facilities
- Manufacturing plants
- Large-scale retail warehouses
- Pharmaceutical and packaging operations
Real-World Impact: A Smarter, Safer Worksite
We’ve implemented Mag Lock Barrier Systems for customers across New Zealand, and the results speak for themselves:
- Near misses drop dramatically
- Pedestrian compliance increases
- Operational flow becomes more controlled
- Team confidence in site safety improves
As Rhys puts it:
“If you have a warehouse environment where you’ve been recording too many near misses, please get in touch. We’ll be happy to help you out.”
Proactive Safety is Smart Business
Mag Lock Barriers aren’t just a gate – they’re a smart, automated safety barrier that helps you take control of pedestrian and vehicle interactions on your warehouse floor.
If you’re serious about reducing risk, improving compliance, and future proofing your operations, Mag Lock Barriers are one of the smartest investments you can make.
Ulti Group is here to guide you every step of the way – from design and configuration to full installation and staff training.
👉 Ready to take the next step? Contact us to discuss how Mag Lock Barriers could transform your warehouse safety
Your team deserves a safer work environment. Let’s build it together.
Let’s Hear From You
Have you experienced a near miss in your warehouse? What steps have you taken to improve safety?
Leave a comment below – we’d love to hear your story.
And if this blog helped you, share it with your H&S team or warehouse manager. A simple solution like this might just prevent the next big incident.