sustAGE · Project

AI Platform That Keeps Aging Workers Productive, Safe, and Employed Longer

healthTestedTRL 5

Imagine your best factory workers are getting older, and you're losing their expertise because the job is wearing them down. This project built a smart system — think Fitbit meets workplace coach — that uses IoT sensors and machine learning to track how workers are doing, recommend personalized training (both mental and physical), warn about safety risks, and help managers assign the right people to the right tasks. It was tested in two real industrial settings across Europe, combining seven different technologies including gamification to keep workers engaged.

By the numbers

EUR 3,999,166

EU funding for development

consortium partners

countries involved (DE, EL, ES, IT)

industrial sectors for deployment and validation

strategic technology trends integrated

total project deliverables

40%

industry ratio in consortium

The business problem

What needed solving

European industries face a growing crisis: their most experienced workers are aging, and there is no integrated way to keep them productive, safe, and engaged without burning them out. Companies lose institutional knowledge when older workers leave early, while rising absenteeism and occupational health costs eat into margins. Current wellness programs are disconnected from actual work tasks and don't adapt to individual needs.

The solution

What was built

The sustAGE platform — an integrated system combining IoT sensors, machine learning, recommender systems, temporal reasoning, data analytics, and gamification. It guides workers on tasks, recommends personalized cognitive and physical training, delivers real-time occupational risk warnings, and optimizes team task assignments. The project produced 27 deliverables and validated the system in two industrial sectors.

Audience

Who needs this

Manufacturing plant managers dealing with aging production line workersHR directors at companies with 30%+ workforce over age 50Occupational health and safety consultants serving industrial clientsHR technology companies looking to add workforce sustainability featuresLogistics and warehousing operators with physically demanding roles

Business applications

Who can put this to work

Automotive Manufacturing

enterprise

Target: Mid-to-large automotive manufacturers with aging production line workers

If you are an automotive manufacturer dealing with rising absenteeism and declining productivity among your 50+ workforce — this project developed an IoT and ML-powered platform that monitors worker well-being in real time, recommends personalized physical and cognitive training, and optimizes task assignments to maximize team performance. The system was validated in two industrial sectors with 10 consortium partners across 4 countries.

Logistics & Warehousing

mid-size

Target: Warehouse operators and logistics companies with physically demanding roles

If you are a logistics company struggling to retain experienced warehouse staff as they age out of physically demanding roles — this project built a recommender system that delivers personalized warnings about occupational risks, suggests adapted work routines, and uses gamification to keep workers engaged in health-promoting activities. The platform integrates with daily work activities rather than adding separate wellness programs.

Occupational Health & HR Technology

any

Target: HR tech companies and occupational health service providers

If you are an HR tech provider looking to add workforce sustainability features to your platform — this project created a composite system combining IoT, machine learning, temporal reasoning, and data analytics for workforce management. With EUR 3,999,166 in EU funding and 27 deliverables produced, the technology covers everything from real-time risk warnings to retirement transition support.

Frequently asked

Quick answers

What would it cost to implement this system in our facility?

The project received EUR 3,999,166 in EU funding across 10 partners over 3.5 years, suggesting significant R&D investment behind this platform. Based on available project data, specific licensing or per-seat pricing is not published. You would need to contact the consortium to discuss deployment costs for your scale.

Can this scale to a plant with hundreds or thousands of workers?

The platform was designed for deployment in industrial settings and combines IoT sensors, machine learning, and data analytics — all technologies that scale well. The system was validated in two critical industrial sectors. However, specific data on maximum concurrent users or infrastructure requirements is not available from published deliverables.

Who owns the IP and can we license this technology?

The project was funded as a Research and Innovation Action (RIA), meaning IP typically stays with the consortium partners. The coordinator is IDRYMA TECHNOLOGIAS KAI EREVNAS in Greece. Licensing arrangements would need to be negotiated with the relevant consortium members who developed specific components.

Does this comply with EU workplace health and safety regulations?

The project was funded under the EU's SC1-DTH-03-2018 topic, directly aligned with EU priorities on digital health and sustainable work. The platform addresses occupational risk warnings and worker well-being monitoring, which align with EU workplace safety directives. Specific regulatory certifications are not detailed in available data.

How long does implementation take?

The full R&D cycle ran from January 2019 to June 2022 (3.5 years). Based on available project data, a deployment timeline for an individual company is not specified. The system integrates with daily work activities, which suggests a phased rollout approach would be needed.

Does it integrate with our existing HR and ERP systems?

The platform was built to integrate with daily activities at work and outside work. It combines IoT, recommender systems, and data analytics. Based on available project data, specific ERP or HRIS integrations are not documented, but the architecture uses standard IoT and ML components that typically support integration.

Is there ongoing technical support available?

The project closed in June 2022. The consortium included 4 industry partners and 2 SMEs who may offer commercial support. The project website at sustAGE.eu may have current contact information for post-project services.

Consortium

Who built it

The sustAGE consortium brings together 10 partners across 4 European countries (Germany, Greece, Spain, Italy), with a balanced mix of 4 industry players, 4 universities, and 2 research organizations. The 40% industry ratio and presence of 2 SMEs indicate genuine commercial interest beyond pure academia. The coordinator is a Greek research foundation (IDRYMA TECHNOLOGIAS KAI EREVNAS). With EUR 3,999,166 in EU funding and 27 deliverables, this was a well-resourced effort. The multi-country spread across Southern and Central Europe suggests the solution was designed for diverse industrial contexts, not a single national market.

IDRYMA TECHNOLOGIAS KAI EREVNASCoordinator · EL
UNIVERSIDAD NACIONAL DE EDUCACION A DISTANCIAparticipant · ES
CENTRO RICERCHE FIAT SCPAparticipant · IT
ARISTOTELIO PANEPISTIMIO THESSALONIKISparticipant · EL
SOFTWARE AGparticipant · DE
AEGIS IT RESEARCH GMBHparticipant · DE
UNIVERSITAET AUGSBURGparticipant · DE
IMAGINARY SRLparticipant · IT
FORSCHUNGSGESELLSCHAFT FUR ARBEITSPHYSIOLOGIE UND ARBEITSSCHUTZ EVparticipant · DE

How to reach the team

The coordinator is IDRYMA TECHNOLOGIAS KAI EREVNAS in Greece. SciTransfer can facilitate an introduction to the project team.

Order a report on this consortium See IDRYMA TECHNOLOGIAS KAI EREVNAS profile →

Next steps

Talk to the team behind this work.

Want to explore how sustAGE technology could help your aging workforce stay productive? SciTransfer can connect you with the research team and help evaluate fit for your operations.

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