Conveyor Safety - Best Practices for Reducing Workplace Accidents

Conveyors are a trusted, reliable, and integral part of modern industrial operations, helping businesses to streamline their material handling activities. Extremely versatile, common conveyor systems have long been used for applications across a wide range of sectors, including e-commerce, retail, grocery, food & beverage, manufacturing, and third-party logistics (3PL). However, as with all automated equipment, conveyors can pose significant potential hazards and potential risks to worker safety without the proper safety measures in place. Therefore, implementing best safety practices in conveyor safety is crucial for reducing the risk of accidents, workplace injury, and ensuring a safe operation and efficient working environment.

Types of Conveyors and Common Industrial Applications

Understanding the different types of conveyors and their suitability for various applications helps to tailor safety measures to specific operations. By ensuring safety elements deliver the right safety levels that are appropriate for required automated handling tasks, businesses will not only protect their workforce but also enable efficiency and productivity to be optimised.

Hygienic Conveyors

Belt Conveyors

Belt conveyors are commonly used in warehouses, manufacturing, and retail distribution. They efficiently move goods from one location to another and are widely used in e-commerce fulfilment centres and for post and parcel sortation.

Roller Conveyors

Roller conveyors are frequently found in grocery warehouses and food & beverage processing plants. They help transport bulk and packaged goods efficiently.

Chain Conveyors

Chain conveyors are popular in manufacturing environments with more robust requirements. They handle heavy loads such as automotive components and metal fabrications.

Overhead Conveyors

Overhead conveyors are used in industries such as manufacturing, fashion, and 3PL. They transport items overhead, freeing up valuable floor space.

Screw Conveyors

Screw conveyors are frequently employed in the food & beverage sector. They handle granular and powdery materials such as flour and sugar.

Pneumatic Conveyors

Pneumatic conveyors are used in industries requiring sanitary conditions, such as pharmaceuticals and food processing. These systems use air pressure to transport bulk or fragile materials, thereby maintaining product integrity.

Key Safety Features for Conveyor Systems

To mitigate the risks associated with operating conveyor systems even with limited or no manual handling requirements, the following safety features can be integrated across all conveyor types:

Emergency Stop Mechanisms: clearly marked and easily accessible emergency stop buttons or pull cords should be installed at regular intervals along the line of conveyors.

Conveyor Guards and Barriers: enclosing moving parts, such as pulleys and gears, with protective guards prevents accidental contact and the potential for becoming caught in the mechanism.

Interlocking Systems: sensors and an automated system can be used to shut down conveyors in case of obstructions or when a worker enters a hazardous zone.

Warning Signal Systems: audible alarms as well as visual signals alert workers when conveyors are starting or stopping.

Conveyor Controls and Anti-Restart Features: limiting the speed of the conveyor and preventing accidental restarts reduce the risk of injury.

Load Sensors and Automated Shutdowns: these features help prevent overloading, which can cause mechanical failures and material spills.

With such a wide range of advanced sensors and systems readily available for automated materials handling tasks using conveyor lines, businesses can achieve high levels of safety, without compromising on efficiency or productivity.

Best Practices for Safe Conveyor Operation

Adopting a culture of safety that incorporates a comprehensive program of checks and policies within warehouses, distribution centres, and manufacturing environments is essential. Here are some best practices that can be integrated into operations:

warehouse-conveyor-systems-3

POST AND PARCEL conveyors

Proper Training Programs

Educate all employees on conveyor operation, safety features, and emergency procedures.

Regular Inspections and Frequent Updates

Conduct routine checks to identify and fix wear-and-tear issues before they become hazards.

Safe Loading and Unloading Procedures

Ensure that materials are correctly placed on conveyors to prevent jams and falling objects.

Clear Signage and Markings

Label danger zones and restricted areas to keep unauthorised personnel away from hazardous sections.

Enforce PPE (Personal Protective Equipment) Usage

Require workers to wear gloves, safety glasses, and other appropriate equipment and clothing when working near conveyors. Avoid loose clothing, baggy clothing and loose clothes that can become entangled.

Encourage a Safety-First Culture

Empower employees to report hazards and participate in continuous improvement initiatives that enhance workplace safety.

Implement Safe Maintenance Procedures

Ensure that conveyors are fully de-energised and shut down at all energy sources during maintenance and servicing to prevent accidental startups.

Prevent Excessive Loads

Ensure that conveyors are not overloaded, as this can lead to mechanical failures and material spills.

UK Regulatory Compliance and Industry Standards

Businesses need to adhere to industry safety regulations, ensuring both legal compliance and protection of workers. There are a number of key UK regulatory bodies and safety standards that are in place to safeguard operations, including:

Health and Safety Executive (HSE): The HSE regulates workplace safety, including conveyors and material handling, under the Health and Safety at Work Act 1974. Employers must conduct risk assessments, implement control measures, and ensure compliance with PUWER (Provision and Use of Work Equipment Regulations). To support UK businesses, HSE provides specific guidance on conveyor safety, including guarding requirements, emergency stop mechanisms, and employee training programs to minimise workplace hazards.

Regulatory Reform (Fire Safety) Order 2005: The primary legislation governing fire safety in UK warehouses, including all workplaces, mandates that all premises must have a fire risk assessment, appropriate fire detection systems, clear escape routes, suitable firefighting equipment, and designated fire safety procedures, with specific emphasis on managing potential fire hazards within the warehouse environment; this includes regular maintenance and checks of all fire safety equipment. Factors affecting the risk of fire by operating a conveyor system include hazardous material (e.g. flammable goods), friction and heat generation by the conveyor itself, electrical components, and the accumulation of dust.

British Standards Institution (BSI): BSI sets a range of safety benchmarks, including BS EN standards, to ensure best practices are followed for machinery safety, risk assessment, and ergonomic design for conveyor systems and other workplace equipment.

International Organisation for Standardisation (ISO): Ensures both UK and global safety best practices for conveyor design and maintenance. The most relevant ISO for conveyor systems, is ISO 9001, which is the primary standard for quality management, and is widely adopted by conveyor system manufacturers to demonstrate their commitment to quality control across all operations. Additional ISO standards such as BS EN ISO12881 relate to a specific focus on conveyor belts, outlining requirements for design, construction, and performance, and BS EN ISO 13857 which is the standard relating to the safety of machinery, including guarding for conveyor systems to prevent access to hazardous areas.

Conclusion

Conveyor systems continue to play a crucial role in industrial efficiency, where worker safety should always be a primary source of concern. By integrating advanced safety features, enforcing best safe work practices, and complying with regulatory safety standards, workplaces can significantly reduce the risk of conveyor accidents.

Businesses that take a proactive approach to conveyor safety not only protect their employees but also enhance productivity and operational efficiency, vital for today’s challenging logistics environment.