Conveyor belt safety

Conveyor systems are the backbone of manufacturing companies, transporting tonnes of materials and products efficiently. However, amid daily operations, worker and conveyor belt safety becomes a critical issue. Fret not, in this blog we will shed light on the common dangers of using conveyor systems and highlight the protocols to maintain conveyor safety in the workplace.

5 Hazards in Conveyor Operations

1. Avoid Pinch Points

Mechanical devices contain chains, belts, and nip points where the conveyor and other components come together, creating a space where fingers or other body parts can get caught and crushed. It’s vital to avoid sneaking your hands into sensitive areas to prevent major accidents. To maintain occupational and conveyor belt safety, use guards or tapes to keep workers from entering hazardous zones.

2. Falling of Heavy Objects

Faulty conveyor belts pose significant health risks to workers and goods. Materials and heavy products can fall off and cause fractures, bruising, and head injuries. It’s a recurring risk because these objects can smash and harm people working in nearby areas. Likewise, many devices and machines may break and lose their operational efficiency.

To maintain optimal conveyor belt safety regulations, the staff should be adequately trained to handle high-risk zones. 

3. Electrical Failure

The number 1 risk to conveyor belt safety is electrical hazards and short circuits. People working in manufacturing, transport, and distribution facilities understand that the possibility of explosions, electric shocks, or fires is real. These belts are made using motors, sensors, and components that may malfunction without proper maintenance and installation. Therefore, conveyor belt selection is a major investment for the smooth functioning of the plant. 

4. Ignoring Safety Training

Most supply chain and logistic companies do not invest in training their staff to handle conveyor belts. Employees should be well-versed in conveyor belt safety signs before they start working. Additionally, organizations should allocate adequate funds to implement monthly or quarterly refresher training programs to facilitate regular monitoring of standards. 

5. Sharp Edges & Entanglement

It’s best to keep clothes, hair and, other loose items away from moving machinery and equipment. In the case of conveyor belts, clothes and jewellery will easily latch onto the machines, posing severe damage to safety and health. Accidents can lead to severe injuries, bruising, wounds, lacerations and even death. 

Furthermore, heavy machinery contains jagged areas and sharp edges posing a threat to conveyor belt safety protocols. If a worker accidentally comes into contact, the sharp wounds can lead to infections and blood loss, contaminating the workplace. 

Next, let’s understand the top conveyor safety tips to prevent major accidents and boost operational efficiency. 

6 Safety Procedures 

Manufacturing hazards are a common occurrence but taking precautions will reduce accidents and save many lives. Here are a few conveyor belt safety processes that can be implemented in a production plant. 

1. Conveyor Training

Whether you are a small company or a large multinational brand, conveyor belt safety precautions dictate that employees should be adequately trained to use belts and conveyor chains. They should never ignore the warning signals attached to these machines and alert visitors to stay away from the high-risk zones. 

2. Quick Management Alert

Many times, severe injuries can be averted if timely diagnosis is followed. If you notice any malfunction or operational concern (e.g. loose guards and fused wires) alert the person in charge of the area. Prepare a conveyor safety inspection checklist guide and explain the emergency SOP guidelines to all employees. 

Make sure everybody knows the point of contact and the person to reach out to during critical situations. 

3. Regular Inspection and Maintenance

Machines require periodic checks and maintenance and almost 80-90% of manufacturing accidents are the cause of faulty conveyor belt safety equipment and machinery. Conducting regulatory checks will help you identify the wear and tear or issues compromising safety. 

Secure the systems with proper locks and tags before starting the repair work. This ensures the machines don’t get powered up in the middle of maintenance, avoiding exposure to life-threatening injuries. 

4. LEV Systems

Airborne dust and pollution can affect the operational safety of conveyor systems and degrade the health of the ground staff. Installing Local Exhaust Ventilation(LEV) helps filter the air as the dust is collected in exhaust ducts and released through the ventilation system. 

Allow only authorized personnel to operate and maintain the exhaust ducts. These safety measures will enhance the effectiveness of on-duty staff, mitigating any untoward incidents. 

5. Check the Guards and Tags 

Conveyors have gears and various moving parts that are dangerous and workers should not be allowed to alter, remove or, change the conveyor guards, protecting them against harmful contact. The tags are made with small openings so your skin, hair, or any body part can’t get inside the belt. 

6. No Physical Contact and Use Easy-to-Read Signs

The last and final step in the conveyor belt safety guide is ensuring the belts are not occupied by any worker. People should never sit, walk, or stand on the belt as legs stuck in a pinch point will cause fatal accidents. 

Inspect your controls to turn on the proper settings without allowing the workers to alter, change, or modify any button. Moreover, use easy-to-read, accessible signs to navigate the plant and place emergency brakes in high-activity areas and sensitive zones. 

Wrapping up, the safety tips ensure that conveyor belts remain in good condition without compromising the safety of workers. Additionally, implementing automation can enhance the efficiency of manufacturing facilities as reduced human assistance will decrease the chances of faults and accidents. 

Finally, let’s address the commonly asked queries to gain a complete understanding of the safety procedure.

FAQs – Conveyor Belt Safety: Tips for Preventing Accidents At Workplace

What is the factor of safety for conveyor belts?

The belts have various tensile strengths and safety factors depending on the components, packaging, and manufacturing processes. It’s best to ascertain the cumulative power of the conveyor belts before proceeding with its operation. 

What are the requirements of a conveyor belt?

To facilitate conveyor belt safety, ensure the belt has the load capacity to handle maximum operational tension throughout its service life. This differs but an average working load value is 10-15% of the max operational breaking load of the belt. 

What is the basic working principle of a belt conveyor system?

The belts are stretched across two or more pulleys and form a closed loop so the belt can rotate. The pulley tows the belt moving the items to different places. 


Conveyor belts are the lifelines of manufacturing and transport production companies. However, to ensure conveyor belt safety, due diligence and periodic inspection are mandatory to prevent harmful accidents and maintenance downtime.  If you are into supply chain management and unable to achieve efficiency, get in touch with Qodenext to fuel your logistical operations in 2024.

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