Major UK Packaging Manufacturer Unlocks £750K in Funding and Cuts Safety Events by 62% with Protex AI
How a leading packaging company used Protex AI to enhance its culture and unlock operational efficiencies with real-time data.
The Impact in Numbers
in environmental grant funding
reduction in safety events
reduction in area control risks
Legacy Reporting Systems and Lack of Visibility
This UK-based packaging manufacturer valued safety, but their processes primarily depended on manual reporting and informal communication. Near-miss data was inconsistent, making it difficult to detect trends or take timely action.
The safety team had a clear goal: to enhance their existing practices with a more transparent and data-informed approach, without compromising operational flow or creating friction with production teams.
“Protex is helping us build an even stronger safety culture. We’ve always been safety-first—but now we’ve got the data to prove what’s working.”
Real-time Insights for Safer Behaviours and Smarter Operations
Deploying Protex AI gave the team a real-time, data-backed view into daily operations. Near-miss reporting surged by more than 500%: a clear indicator of insights that had previously gone unnoticed.
While the platform was introduced to enhance safety oversight, it quickly revealed deeper operational insights to optimize systems and reduce risk.
Better Layouts and Fewer Incidents
The Problem: Employees unknowingly entered restricted areas. Forklift and pedestrian traffic often overlapped, but without hard data, layout changes were hard to justify.
Protex AI’s Impact: Protex AI helped the team detect highly congested areas, blind spots, and walkway violations. Rules detecting “line crossing” and unauthorized door use provided clear evidence for targeted changes.
Layouts were redesigned for improved flow and safety
Walkway upgrades were prioritized and implemented
Resulted in a 62% drop in safety events in a single month, and a 92% reduction in area control risks
“Within just a couple of hours, Protex AI showed how people actually moved through the site. That data helped us make effective changes quickly.”
Unlocking Funding and Efficiency
The Problem: To meet funding requirements for environmental grants, the company relied on employees to manually snap photos of each load that came in: one of the truck’s licence plate, and one that showed the recyclable materials inside. . This process led to blurry photos, missing documentation, and lost grant revenue - up to £500 per truck.Employees unknowingly entered restricted areas. Forklift and pedestrian traffic often overlapped, but without hard data, layout changes were hard to justify.
Protex AI’s Impact: The team used Protex AI to capture accurate and compliant visual proof. This helped recover £750K that would have otherwise been lost: half of their total annual funding.
“The time-lapse feature alone paid for Protex AI many times over.”
Gain Full Visibility To Risk Across
Your Warehousing Operations
Companies worldwide trust Protex AI to enhance workplace safety and empower their workforce. Learn how our AI-driven solutions proactively protect employees and improve operational efficiency.
A Platform for Continuous Improvement
Protex AI is now an integral part of daily operations for this UK packaging leader, supporting safety initiatives and enhancing cross-functional operational alignment.
By embedding real-time insights into their daily routines and safety meetings, the team has enabled the following improvements in their safety culture:
Improved visibility across teams: EHS, Operations, and other departments work from the same clear, actionable data.
A more engaged and accountable workforce: Data from Protex AI helps build trust, as teams can clearly see which changes are working and where to focus next.
Faster responses: “If something needs quick attention, I just send a link and say, ‘Take a look at this area,’” said the site’s Health & Safety Manager.
“The team can see what we’re doing, and more importantly that there are clear benefits. We’re not trying to get anyone in trouble, we just want everyone to get home safe.”
