Building Intelligent Safety Ecosystems for Automated Intralogistics
As warehouses and material handling systems advance toward high-speed automation, integrated functional safety becomes essential. From conveyors and AS/RS to AMRs and palletising cells, smart safety technologies now ensure compliance, uptime, and seamless human–machine collaboration across Industry 4.0 environments.
In what ways does Schmersal support machine safety requirements in logistics and intralogistics applications?
Schmersal supports logistics and intralogistics by offering an integrated safety ecosystem that protects people and ensures uninterrupted material flow. Across conveyors, ASRS, AGVs, and automated warehouses, We provide end to end safety ecosystem — Safety Sensors, Pull cord switches, Door Interlocks, Safety light curtain, Safety scanners and Safety Relays/Controllers, Decentralized Safety fieldbus I/O, Safety fence and tecnicum – Solution and Services purpose built for AS/RS, conveyors, palletising cells, monorails, and industrial trucks, with a core focus on high availability and predictive diagnostics for Industry 4.0 plants. The portfolio is engineered to achieve PL d/e (EN ISO 13849 1 / IS 16810) and SIL per IEC 62061 / IS 16501 through correct architecture and validation, complemented by EN/IEC 61496 / IS 16502 for AOPDs like light curtains.
tec.nicum provides manufacturer neutral risk assessment and conformity services aligned to ISO 12100 / IS 16819, ensuring compliance for Indian and global deployments. Our portfolio from Germany, complemented by locally engineered products in India, helps customers achieve compliance with global safety standards while improving reliability and uptime.
Which of your safety solutions are most relevant for warehouses, conveyors, and material handling systems?
For warehouses and material handling setups, Schmersal brings a combination of smart electronic safety devices and rugged electromechanical switches suited to demanding conveyor environments. For conveyor lines, we are giving complete solutions like Safety limit switches, Solenoid interlocks, Pull wire switches, E-Stop switch, Belt sway, Safety fence. We also offer cutting edge contactless protective devices such as safety light curtains, laser scanners, and multi beam barriers, which enhance flexibility and optimize space usage, especially in palletizing, packaging, and high density storage systems. These devices incorporate intelligent features like muting, blanking, and advanced diagnostics, further improving safety without compromising throughput.
Additionally, Access protection uses RFID solenoid interlocks (AZM series) and control panels (BDF200) evaluated by PSC1 safety controllers to achieve required PL/SIL, large applications reduce wiring via the Safety Fieldbox (PROFINET/PROFIsafe, EtherNet/IP CIP Safety, EtherCAT FSoE) for eight safety devices, improving diagnostics and uptime. latest SSB R magnet track sensor box provides highly precise speed and position monitoring for electric monorail conveyor systems, helping logistics customers achieve more efficient, space saving, and reliable transport within warehouses.
System design and validation follow EN ISO 13849 1 / IS 16810 and IEC 62061 / IS 16501 for safety related control systems. Schmersal continually introduces new technologies tailored to intralogistics. Overall, Schmersal’s intralogistics solutions combine robust safety engineering, predictive diagnostics, and Industry 4.0 connectivity, helping customers create safer, more efficient, and more productive warehouse environments.”
How does local manufacturing in India strengthen your offering for logistics customers?
Local manufacturing is one of the biggest strengths of Schmersal India, especially for logistics and warehouse automation customers. Since we manufacture key products in our Pune facility and customized solutions, we can offer much faster delivery compared to imported solutions. This is crucial for logistics customers who run 24×7 operations where any delay directly affects throughput.
From a commercial perspective, domestic manufacturing protects customers from currency fluctuations and import duties, making our pricing more stable and competitive for large scale rollouts and because our Engineering, Application, and Service teams are all based in India, customers get faster on site support, quick validation, and immediate availability of spares.
What role does functional safety play as logistics operations move toward higher automation?
As logistics operations shift towards automated, software-driven workflows, functional safety becomes a core requirement for risk-free operation. High-speed conveyors, shuttle systems, and AGVs demand accurate sensing, controlled stopping, and real-time diagnostics to prevent accidents. Functional safety ensures predictable machine behaviour, enabling humans and machines to coexist safely and improving system uptime and reliability as AGVs/AMRs, shuttle systems, and high speed sortation scale, functional safety ensures predictable stop functions, diagnostic transparency, and safe human machine coexistence across zones. Schmersal architectures combine Type 4 AOPDs and interlocks with PSC1 logic (PL e/SIL targets) and decentralized fieldboxes to meet risk reduction goals under EN ISO 13849 1 / IS 16810 and IEC 62061 / IS 16501, validated per the standards. tec.nicum closes the loop with risk assessments and verification in line with ISO 12100 / IS 16819, helping operators achieve conformity and uptime simultaneously.
What key solutions will be showcased by you at LogiMat Expo?
At LogiMAT, Schmersal highlights solutions that enhance both operator protection and system intelligence for modern warehouses.
We are showcasing the live AMR with integrated Safety solutions and advanced safety AZM RFID interlocks plus BDF200 access panels for safe entry, PSC1 safety controllers and the Safety Fieldbox to cut wiring and expose richer diagnostics over PROFIsafe/CIP Safety/FSoE and Safety light curtains, Laser scanners.
And Local manufactured solutions like Safety door switches, E-Stop, Safety Interlocks, Pull wire switches and Safety fence. The focus is on demonstrating how safety can support higher productivity and meet the growing demand for automated warehousing in India.
Which logistics or intralogistics trends observed at LogiMAT will be influencing your product strategy?
Trends such as rapid adoption of robotics, high-density warehousing, and the need for seamless human-machine collaboration strongly influence our product direction. Customers increasingly expect connected safety devices with diagnostic capability and easier integration into IT/OT networks. These trends drive us to enhance digital features, improve flexibility, and develop compact, intelligent safety components aligned with global intralogistics advancements.
Schmersal’s response is more compact interlocks, smarter AOPDs with muting/teachable zones, and fieldbus native safety to simplify large installations. Extended diagnostics from devices and boxes support condition based service and predictive maintenance, directly improving OEE while staying within PL/SIL frameworks defined by EN ISO 13849 1 / IS 16810 and IEC 62061 / IS 16501
Are there any new or upgraded safety solutions being highlighted for logistics applications at the expo?
Schmersal is presenting upgrades to its sensing and control ecosystem designed specifically for logistics, including improved safety light curtains with muting, new-generation laser scanners for mobile robots, and advanced RFID-based interlock systems. These developments provide higher reliability and connectivity, making them ideal for dynamic warehouse environments. They also support faster maintenance and better predictive monitoring. Recent enhancements include SLC/SLG 445 functions (muting, multi scan) to keep material moving without nuisance stops and Safety Fieldbox variants for multiple safe fieldbuses, enabling true plug and play across eight mixed safety devices. These updates are applied under IEC 61496 / IS 16502 for AOPDs and integrated into safety controls designed/validated to ISO 13849 1 / IS 16810 or IEC 62061 / IS 16501, depending on the risk analysis. These solutions are designed to minimize downtime, support predictive maintenance, and ensure safe yet efficient handling in order picking and palletizing operations.
Overall, Schmersal enables high productivity and reliable safety across automated and interconnected intralogistics environments
How do you work with OEMs and system integrators in the logistics sector?
We work closely with OEMs and system integrators by supporting them from concept to commissioning through engineering guidance, safety calculations, system design, and compliance consulting. Our technical team assists in selecting the right safety architecture, resolving application challenges, and conducting site audits. This collaborative approach helps logistics OEMs build safer, globally compliant machines with reduced development time.
Schmersal co engineers safety from concept to SAT: device selection, safety function design, SISTEMA based PL checks or SIL calculation, controller programming, and documentation—delivered product neutrally by tec.nicum. Engagements culminate in validation per ISO 13849 2 / IS 16810 2 or IEC 62061 and risk reduction per ISO 12100 / IS 16819, ensuring machines are compliant whether commissioned in India or exported.
What opportunities do platforms like LogiMAT Expo create for collaboration and market growth?
LogiMAT provides a platform for Schmersal to engage directly with decision-makers in warehouse automation, understand evolving safety needs, and showcase technological strengths. It opens opportunities for partnerships, multi-location deployments, and long-term collaboration with both Indian and global integrators. The event helps reinforce our position as a trusted safety partner in the expanding logistics ecosystem.
LogiMAT accelerates direct dialogue with 3PLs, ecommerce warehousing, and automation OEMs, letting us demonstrate tangible CAPEX/OPEX wins from fieldbus ready safety and diagnostics rich devices in real use cases. It also enables workshops on Indian IS adoptions and global ISO/IEC alignment so cross border projects select architectures that pass both EU and Indian conformity pathways without re engineering
How does Schmersal India view the role of AI and machine connectivity in future safety systems? Schmersal views AI and connectivity as key enablers of the next generation of safety systems, where devices will not only protect but also predict and prevent failures. With increased machine-to-machine communication, safety components will deliver richer diagnostics and integrate with cloud platforms for predictive maintenance. AI-driven safety analytics will support dynamic protection zones, especially in environments with robots and AGVs, making warehouses safer and smarter. We see AI and connect diagnostics elevating safety from reactive to predictive: devices and controllers will surface health/state data for maintenance planning and dynamically adapt protection (e.g., speed dependent zones for mobile systems) while remaining mapped to PL/SIL claims. Schmersal’s approach is to keep the safety function compliant to ISO 13849 / IS 16810 or IEC 62061 / IS 16501 and let analytics/AI live alongside via secure fieldbus and cloud interfaces—supported by tecnicum consulting on standards, validation, and documentation