Industry
Material handling
PROSTART® with immobilisation for forklifts. RFID operator ID. HRWL expiry tracking. Hours-based maintenance.
The pain
The problems we solve in material handling
HRWL ticket expiries slip through
High-Risk Work Licences (LF, TF, WP, others) expire every five years. Multi-site forklift operations lose track. An expired ticket means an uninsured operator on a registered machine, and a sleepless WHS manager.
Pre-starts that don't enforce
Forklift pre-starts are mandated under WHS regulations. Most fleets do them on a paper book on a clipboard, or a tick-box app. The truck starts whether the operator passed or not. Nothing physically stops a damaged forklift being used.
Near-miss reporting in pedestrian zones
DCs and warehouses are pedestrian-heavy. Near-miss data lives in paper incident books or in someone's email. By the time the trend is visible, somebody's been hit.
Asset utilisation guessing
Some forklifts run 12 hours a day; some sit idle for weeks. Without hour-level data you over-buy in one part of the fleet and under-spec in another. CAPEX decisions get made on gut feel.
Hours-based servicing missed
Forklifts service on engine hours, not weeks. Preventative and routine maintenance triggered at the 250 or 500-hour thresholds keeps machines reliable and on the road.
How Teletrack fixes it
Five capabilities for forklift fleets.
PROSTART® pre-starts with immobilisation
The forklift won't start until the pre-start passes. Operator is identified by RFID card, iButton, or keypad. Daily safety checklist runs on a tablet or the forklift display. Fails immobilise the truck and auto-generate a maintenance work order. Tamper-evident audit log for WHS evidence.
See PROSTART® →Operator ID with HRWL expiry tracking
Operators are linked to their HRWL number and class. Ticket expiry is tracked in the platform — alerts ahead of expiry, and the operator can be blocked from pre-starting a machine class their licence doesn't cover. Reduces the chance of an expired-ticket operator running a regulated machine.
Hours-based maintenance
Engine hours flow from the tracker straight into the maintenance module. 250, 500, 1,000-hour services trigger work orders automatically. Parts inventory and stock movements tracked. Technicians complete work orders on tablet with photo and signature capture.
See maintenance →Pedestrian monitoring via Proxicam
Active pedestrian detection in warehouses and distribution centres is handled by a Proxicam install — a separate camera-and-sensor system that watches for pedestrian incursion into the forklift's working zone. Useful for high-traffic DCs and warehouses where the near-miss problem is the most expensive risk on the floor.
Driver scorecard for safe operating
Harsh acceleration, harsh braking, impact events (where the device supports it), and over-speed get scored per operator. Ranked weekly report. Useful for operator coaching, insurance discount negotiation, and pre-incident behaviour patterns.
See driver scorecard →Recommended hardware
We pick the device that fits the machine.
For forklifts and telehandlers (hardwired)
Ruptela Smart5 or Teltonika FMM250 — hardwired with relay output, PROSTART-ready with immobilisation, full CAN reads where the machine exposes it. Suits IC and electric forklifts, reach trucks, order pickers, telehandlers, scissor lifts, and boom lifts.
See hardware →For forklifts and telehandlers with dashcams
Teltonika FMC650 — same hardwired telematics + supports the Teltonika Dashcam (single forward-facing) and DualCam (forward + driver-facing). Useful where insurer requirements or DC-floor incident review need video alongside the telematics.
See dashcams →Cabin-mounted Android tablet for pre-starts
Topicon MDT865 — rugged Android tablet that mounts in the operator's cabin, runs the Teletrack Android app for pre-starts and operator workflow. Useful where the operator needs a dedicated in-cabin screen rather than a personal phone or handheld. Pricing is enquire-only — get in touch via the contact page.
Topicon MDT865 spec sheet →Pedestrian monitoring add-on (Proxicam)
For warehouses and DCs where pedestrian near-miss is the headline risk, a Proxicam install pairs with the forklift to actively monitor pedestrian incursion into the working zone. Separate hardware install on top of the Teletrack tracker.
HRWL-aware
Forklift operations carry primary safety duty under state regulations, plus the national HRWL framework. Teletrack's audit trail supports both: operators identified by HRWL class and number with expiry tracking, tamper-evident pre-start records per machine per shift, incident reports linked to operator and machine, maintenance records aligned with manufacturer hour intervals. Data hosted in AWS Sydney.
Pricing
Three plans. Real numbers. All ex GST. Month-to-month.
- Track — $21.90 / asset / month — tracking, geofencing, alerts, driver scorecard.
- Track + Safety — $26.90 / asset / month — Track plus the Maintenance Module bundled with pre-start checks (no immobilisation).
- Track + PROSTART® — $31.90 / asset / month — Track plus Maintenance + PROSTART® with cross-vendor immobilisation + managed 6-stage rollout. Recommended for forklift fleets.
- Full Suite — Track + PROSTART® ($31.90) + operational modules package — Timesheets + Inductions + Dockets at $5 / user / month total.
Common questions
How does forklift immobilisation actually work?
The tracker (Ruptela Smart5, Teltonika FMM250, or Teltonika FMC650 if you're also fitting a dashcam) is hardwired into the forklift with a relay on the ignition or starter circuit. When pre-start fails or an unidentified operator attempts to start the machine, the relay holds the start circuit open. Override is supervisor-only and logged. Re-engagement after a passed pre-start is automatic.
Can the operator ID work with our existing RFID cards?
Yes in most cases. We support standard RFID card readers (125 kHz and 13.56 MHz MIFARE), iButton, and keypad PIN entry. If your facility already issues RFID cards for door access, we can usually read them. We confirm compatibility during pre-install consultation.
How does HRWL tracking work day-to-day?
Each operator is set up with their HRWL number, class (LF, TF, WP, etc.), and expiry date. The platform alerts ahead of expiry — typically 30 / 60 / 90 day reminders. Operators can be configured to be blocked from pre-starting a machine class their licence doesn't cover, or just flagged to the supervisor — your call.
Does GPS work indoors?
Standard GPS is unreliable indoors. For outdoor / open-yard work it's fine. Indoor zone-level positioning isn't a feature of the platform today — operations that need it usually rely on the PROSTART® pre-start + operator-ID + maintenance trail rather than aisle-precise indoor location.
Can we run telehandlers and scissor lifts on the same platform?
Yes — and two of our whitelabel partners are exactly that (a scissor-lift programme and a rotating-telehandler programme). Same platform, same hardware bench. You can mix forklifts, reach trucks, telehandlers, and scissor lifts on one Teletrack subscription.
What about impact / collision events?
The Smart5, FMM250, and FMC650 detect impact events via accelerometer thresholds. Events are logged with time, location, operator ID, and the surrounding telemetry. Useful for post-incident review, near-miss trending, and damage cost recovery. Not a substitute for a dedicated collision-avoidance system or for Proxicam pedestrian monitoring, but it captures and reports what happened.
Do you integrate with our WMS or ERP?
We have an open API and we've integrated with various WMS / ERP systems for customers — utilisation data into asset-management systems, work order sync with maintenance systems. If you've got a specific WMS / ERP in mind, ask us during discovery and we'll scope the integration.
How long to deploy on a 50-forklift fleet?
Typical 50-forklift deployment is 2 to 4 weeks. Hardware installs via our auto-electrician partner network — predictable per-asset rates. PROSTART® rollout follows our 6-stage process, included on Track + PROSTART®.
What about pedestrian monitoring?
Pedestrian monitoring on the DC or warehouse floor is handled by a Proxicam install — a separate camera-and-sensor system that watches for pedestrians entering the forklift's working zone and alerts the operator. It's an add-on to the Teletrack tracker on the asset, not a built-in feature of the platform. Useful for high-traffic DCs where the near-miss problem is the most expensive risk on the floor.
Can I run the pre-start on a cabin-mounted tablet?
Yes — the Topicon MDT865 rugged Android tablet mounts in the operator's cabin and runs the Teletrack Android app for pre-starts and the operator workflow. Useful where the operator needs a dedicated in-cabin screen rather than a personal phone or handheld. Topicon MDT865 spec sheet. Enquire for pricing.
See Teletrack on your forklift fleet
A 30-minute demo will show PROSTART® on a forklift with immobilisation, the HRWL expiry workflow, and the operator-ID setup — using a fleet make-up that matches yours.
Want a walkthrough tailored to material handling?
Book a 30-min demo