Food, Beverage, & Grocery | Distribution Center
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Situation Overview
Operating in the food, beverage, and grocery retail sector, this distribution center faced significant challenges due to the nature of its fast-paced, high-volume environment. Cold storage areas, wet surfaces, multi-level layouts, and constant movement of goods increased the risk of slips, trips, and falls. Frequent use of ladders and stairs in cluttered zones, combined with a mix of full-time and temporary workers, further elevated the potential for accidents.
Food, Beverage, and Grocery Distribution Center
Why fall protection is needed
Fall hazards were present throughout the facility—from roof access points to elevated equipment areas. With the facility’s operational model depending on speed and uptime, even a single safety incident could lead to thousands in unplanned costs, delays, or compliance violations.
According to the National Safety Council, the average cost of a medically consulted injury is $43,000, and a serious fall incident could easily exceed $160,000 in direct and indirect costs. In addition, OSHA violations for fall protection failures can result in fines of over $16,000 per occurrence. Left unaddressed, these risks threatened worker safety, productivity, and audit readiness.
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Safety Excellence & Operational Investment Optimization
Through a comprehensive Roof Safety Audit™, Kattsafe identified multiple fall hazards across the site. The team implemented modular aluminum access platforms, walkways, and guardrail systems designed specifically for cleanability and code compliance in food-grade environments. Engineered rooftop safety systems were installed to protect service personnel during equipment maintenance, ensuring safe access without compromising operations.
By standardizing fall protection systems across the facility, the distribution center achieved measurable returns:
Injury-related downtime was reduced by up to 80%
Potential compliance fines and legal costs—ranging from $50,000 to over $250,000—were avoided
Safety audit disruptions decreased, preserving over $25,000 in potential lost productivity
Improved employee confidence and safety culture across shifts and departments
Roof Safety Audit™ Service
Kattsafe conducted a comprehensive Roof Safety Audit™, identifying key hazard zones and non-compliant access paths. Based on the findings, the facility was outfitted with:
A custom crossover stair system to enable safe, direct access over rooftop piping
A powder-coated aluminum guardrail system with integrated toe board for edge protection and compliance
These systems were installed using non-penetrating methods to preserve the roof membrane and reduce future repair costs.
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Download the brochure for more information on compliant and efficient safety solutions for the food, beverage, and grocery industry
Project photos
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