For employees working in manufacturing environments, heat stress is a serious occupational hazard. At Perrigo, a leading Irish-American manufacturer, workers produce pharmaceuticals and powdered infant formula under conditions where temperatures can rise quickly. Physically demanding tasks in these warm environments put employees at risk of heat-related illness, making proactive safety measures essential.
The Challenge: Heat Risk in Manufacturing
Perrigo’s production facilities include large tower dryers and other equipment that generate significant heat, creating localized “hot spots” where temperatures can spike. In such environments, employees performing physically intensive work face the dual challenge of completing production tasks efficiently while managing their own health and safety.
Historically, Perrigo tracked heat exposure through scheduled breaks, hydration policies, and supervisor oversight. While effective, this approach had limitations; heat-related illnesses still occurred, averaging four to five incidents annually, including hospitalizations. The company recognized the need for a more proactive, data-driven approach to safeguarding employees while maintaining operational continuity.
The Solution: SlateSafety BAND V2 Wearables
To address these challenges, Perrigo implemented the SlateSafety system. Employees wore BAND V2 devices that continuously monitored heart rate, core body temperature, and overall heat strain in real time. These devices gave supervisors actionable insights into workers’ physiological status, allowing for immediate intervention if readings approached unsafe thresholds.
When alerts were triggered, supervisors could take timely steps such as:
- Providing hydration breaks
- Rotating tasks to reduce physical exertion
- Adjusting work/rest cycles
- Redirecting employees away from high-temperature areas
This real-time feedback not only protected workers but also allowed production managers to optimize workflows, scheduling, and staffing in a way that prioritized safety without slowing operations.
Identifying Hot Spots for Targeted Safety Measures
One important outcome of Perrigo’s heat safety program was a better understanding of facility hot spots, which are areas where heat exposure was consistently higher and workers were more likely to experience heat strain. By combining real-time physiological data from the SlateSafety system with on-site observations and environmental monitoring, Perrigo was able to pinpoint these high-risk areas and implement targeted safety strategies, including:
- Dedicated cooling zones where employees could recover
- Spot cooling and ventilation improvements
- Cooling garments for high-risk tasks
- Adjusted work/rest cycles tailored to specific areas and tasks
By integrating wearable monitoring with these environmental and operational measures, Perrigo created a holistic, proactive program to prevent heat stress and protect workers across the facility.
Results: Zero Heat-Related Incidents
The results were immediate and measurable. Since implementing the SlateSafety BAND V2 system, Perrigo has reported zero heat-related illnesses or hospitalizations, a remarkable improvement from the four to five annual incidents previously experienced.
Rob Somers, Director of Environment, Health & Safety at Perrigo, highlighted the impact in a webinar hosted by the National Safety Council and AIHA:
“…Since we implemented [SlateSafety], we haven’t had one heat-related illness or person sent to the hospital, where we averaged 4-5 a year up until that point.”
Beyond reducing incidents, the system has enhanced overall confidence among employees and supervisors. Workers can perform their duties knowing that their physiological status is being monitored in real time, and supervisors can intervene proactively rather than reactively.
Proactive Safety Without Compromising Production
Perrigo’s approach demonstrates that worker safety and operational efficiency are not mutually exclusive. By leveraging real-time wearable technology, the company can protect employees while maintaining production schedules. Supervisors can plan shifts and workloads with precision, ensuring that heat stress is managed effectively without unnecessary interruptions to production.
The SlateSafety BAND V2 system also provides a wealth of data for long-term safety planning. Facility managers can analyze patterns of heat exposure, refine workflows, and implement targeted environmental controls, further minimizing risk. This data-driven approach elevates the company’s safety culture, empowering employees and managers to make informed decisions every day.
A Model for Heat Safety in Manufacturing
Perrigo’s experience offers a blueprint for other manufacturing operations facing similar heat-related risks. By combining wearable monitoring, environmental interventions, and proactive workflows, companies can achieve measurable reductions in heat-related incidents while maintaining productivity.
As workplaces increasingly recognize the value of technology in protecting employees, Perrigo demonstrates how innovation can directly enhance safety outcomes. Wearable devices like the SlateSafety BAND V2 are helping organizations move from reactive strategies to preventive, data-driven programs that safeguard workers and ensure operational continuity.
For employees working in hot, physically demanding environments, the message is clear: proactive monitoring saves lives. Perrigo’s success underscores the importance of integrating technology into workplace safety programs, proving that when safety and innovation go hand in hand, everyone benefits.