EYES ON SAFETY: HOW COMPUTER VISION IS REINVENTING RISK MANAGEMENT IN PULP AND PAPER MILLS

In pulp and paper mills, where heavy machinery, pressurized systems, and chemical exposure transform risk management into a daily challenge, innovation in safety is long overdue. Traditionally, safety leaders have relied on manual audits, sporadic supervision, and legacy surveillance systems to monitor compliance with personal protective equipment (PPE) requirements. These approaches, while well-intentioned, are reactive and prone to human error. Enter tailored computer vision: an intelligent, real-time digital watchdog capable of revolutionizing safety enforcement in these high-risk settings. 

From paper checklists to machine vision: The digital leap 

Manual PPE audits in large industrial settings are labor-intensive and often miss critical deviations. Human supervisors can only be in one place at a time, and time-stamped logs might be out of sync with real behavior. Even sophisticated generic CCTV setups are passive, unable to distinguish a worker missing gloves from one who is fully compliant. 

Radix-configured computer vision solutions move far beyond these limitations by providing: 

• Automated, real-time detection of PPE use across all plant zones. 

• Instant alerts when violations occur—before they cause incidents. 

• Tamper-proof digital records supporting audit readiness. 

Use case 1: Real-time PPE enforcement on the mill floor 

In the heart of pulp and paper production, busy operators cross hazardous zones dozens of times per shift. Hard hats, gloves, safety glasses, earplugs, and high-visibility vests are non-negotiable for safety, but they can be easily overlooked when working under pressure, or in a hurry. With Radix’s computer vision system, strategically placed cameras constantly scan for every PPE item required at each entry point and work zone. 

Here’s how it works: 

• Operators enter a high-noise production hall. 

• The computer vision system instantly recognizes whether each person is wearing mandatory PPE (e.g., detecting the color of the helmet, reflective strips, or glove use). 

• If a missing item is detected, the system sends an immediate alert to both the individual (via SMS, badge vibration, or display) and the safety manager. 

• All violations and interventions are logged in a secure audit trail. 

Impact: 

This proactive, automated approach drastically reduces the time from violation to correction. Studies highlight reductions in PPE-related safety incidents and a proven increase in overall compliance rates, surpassing manual spot-checks that often occur after exposures or near-misses. 

Use case 2: Continuous safety monitoring in high-risk zones 

Certain areas in pulp and paper mills, such as chemical storage zones, confined spaces, or the wet end of the paper machine, pose heightened risks. Here, Radix’s system monitors dwell time, tracks restricted access, and even registers unsafe postures or proximity to hazards. 

Take the following scenario: 

• An operator is working in a confined area where respiratory protection is essential. 

• The vision system cross-references the presence of required respirators and restricts access to those who do not have them. 

• If an unauthorized entry or unsafe posture (e.g., bending over automated rollers) is detected, the shift supervisor receives an instant video clip and data to support

Operational Benefits: 

• Reduces “blind spots” where manual supervision can’t keep up. 

• Supports root-cause analysis after incidents with time-stamped, annotated footage. 

• Provides continuous documentation to satisfy regulatory and insurance requirements. 

Use case 3: Audit readiness and data-driven safety management 

Traditional compliance audits in pulp and paper plants are disruptive and retrospective, relying on memory, paperwork, and scheduled walkthroughs. Radix’s computer vision system transforms this by delivering a living digital compliance record, with the following key features: 

• Automated reporting: The system summarizes compliance metrics, tracks trends by area, shift, and job role. 

• Instant drill-down: Investigators can quickly review video evidence tied to specific safety events. 

• Proactive insights: Safety teams can identify systemic problems (e.g., repeated violations at a specific entry point) and target corrective action where it matters most. 

This level of instant traceability eases the burden of external audits, shortens response time to regulatory inquiries, and positions the mill as a model of best-in-class safety culture. 

Why tailored beats off-the-shelf 

Many generic computer vision products claim “PPE detection,” but Radix’s custom-integrated solution is specifically tuned to the complex realities of the pulp and paper environment: 

• Custom-trained algorithms: Adapted to diverse lighting, worker uniforms, and mill-specific hazards. 

• Integration: Seamless fit with existing security and process control infrastructure; no rip-and-replace. 

• Data sovereignty: Mills retain full ownership and control over their safety data, vital for privacy and long-term adaptability. 

Measured results and industry impact 

Deployments in pulp and paper and related high-risk industries have delivered: 

• Up to 92% PPE compliance post-implementation, compared to 60–70% achieved through audits alone.¹ 

• As much as a 75% reduction in critical safety incidents—not just PPE violations, but also hazard exposures and near-miss events.² 

• A 22% drop in safety-related complaints within months of installation, reflecting improved worker confidence and faster management response.³ 

Looking ahead: Safer, smarter mills 

For safety and operations leaders, the path forward is clear. By leveraging the power of computer vision, mills can transition from a reactive, manual oversight approach to a proactive, data-driven approach that manages—and mitigates—risk in real-time. 

This isn’t about replacing human judgment, but amplifying it. When intelligent vision systems back operators, they can focus on safe, productive work, confident that the eyes of innovation are always on, always watching for their well-being. 

For those driving innovation in health, safety, and operations, custom-integrated computer vision isn’t just an upgrade; it’s a transformation in what modern risk management can and should deliver in pulp and paper mills. 

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About Radix  

Founded in 2010, Radix is a privately held technology solutions and services company operating globally, empowering customers with consulting, engineering, operations technology, and digital solutions. Radix combines key capabilities and practices to enable our worldwide customers to thrive in their technology journey. With North American headquarters in Houston, TX, and headquarters in Rio de Janeiro, Brazil, including offices in São Paulo and Belo Horizonte, Radix provides technology-based, data-driven solutions to asset-intensive industries. Radix's robust capabilities extend to more than 30 countries worldwide. Learn more: www.radixeng.com 

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