The challenge

In high-risk environments like ports, terminals, and logistics hubs, traditional personal protective equipment (PPE) offers physical protection but lacks the ability to detect and respond to dynamic hazards. Workers face risks such as falls, unsafe movements, and environmental threats - often without immediate support or visibility from supervisors. Manual monitoring is limited, and delayed responses can lead to serious injuries or fatalities, especially for lone workers.

The innovation

Melius Italia’s Smart PPE system integrates miniature wireless sensors and low-power AI algorithms into protective gear - without compromising comfort or design. These sensors track:

• Motion and posture to detect falls or unsafe movements
• GPS location for real-time worker tracking
• Environmental data such as temperature and humidity
• Contextual awareness for man-down detection and hazard alerts

The system connects via IoT protocols (BLE, LoRa, Wi-Fi) and feeds data into a secure, cloud-based management platform. Supervisors receive instant alerts and can monitor safety metrics, generate reports, and manage risks remotely.

How it works

Smart PPE is deployed through a multi-step integration process:

1. Sensor-enabled gear is distributed to workers
2. Mobile apps and dashboards provide real-time visibility and alerts
3. Secure data protocols ensure privacy and role-based access
4. Training tools support adoption and proper use
5. Pilot programs and feedback loops refine performance and usability

The system is compatible with existing PPE and designed for seamless integration into daily operations.

Case study

The implementation of smart PPE systems has led to a measurable improvement in workplace safety and operational efficiency. Real-time monitoring has enabled immediate detection of hazards such as falls, unsafe movements, and environmental threats, significantly reducing the risk of injury - especially for lone workers. Instant alerts allow supervisors to respond quickly to incidents, while the system’s accuracy minimises false alarms and ensures resources are focused on genuine threats. Companies have also benefited from improved compliance tracking, automated reporting, and data-driven insights that support proactive safety planning. The intuitive design and seamless integration with existing PPE have encouraged high user adoption, and robust data security measures have helped maintain worker privacy and trust.

Potential impact

Smart PPE is redefining workplace safety in transport and logistics by:

• Enabling real-time hazard detection and response
• Reducing injury rates and improving worker confidence
• Supporting compliance and audit readiness
• Providing scalable, data-rich safety solutions for diverse environments