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What safety measures should be taken when using conveying equipment?

by lisa•

What Safety Measures Should Be Taken When Using Conveying Equipment?

If you’ve ever stood on a factory floor watching our conveying systems move pallets, bulk materials, or components from one end of the line to the other, you know how critical these machines are to keeping operations running smoothly. Over the 12 years I’ve been selling conveying equipment, I’ve seen just how quickly a small oversight can turn a routine task into a dangerous situation. Last year, I visited a manufacturing client in Ohio where an operator reached into a jammed belt conveyor without locking out the machine—luckily, a coworker was nearby to hit the emergency stop, but it still left him with a broken wrist and the plant shut down for three days. That incident stuck with me, because it didn’t have to happen. Safety with conveying equipment isn’t just about following rules; it’s about building habits that protect the people who rely on these machines every single day. Conveying Equipment

First and foremost, lockout/tagout (LOTO) procedures are non-negotiable, no matter how small the job. I know some operators think, “I’ll just turn the power off real quick and fix the jam,” but even when a conveyor looks totally still, residual energy can linger. Hydraulic lines can hold pressure, motor shafts can spin on their own, and gravity can make loaded conveyors tip if they’re not secured. When we install our systems, we provide detailed LOTO manuals for every model we sell, but too many teams skip the step of actually training their staff to use them. At a food processing plant in Indiana that’s been a customer of ours for eight years, they do monthly LOTO drills where each operator practices locking out a conveyor and verifying zero energy flow—they even take turns being the “one in charge” to make sure everyone understands the process isn’t just for new hires. The key here is that LOTO isn’t a one-time training; it’s a routine that needs to be reinforced until it becomes second nature. If you’re not sure if your team is doing LOTO right, ask your conveying equipment supplier to send a safety specialist out for a walkthrough—we do that for free for our long-term customers, and it’s saved more than one client from a preventable accident.

Next up, guarding the moving parts of your conveying system is one of the most effective ways to stop accidents before they start. I’ve seen clients cut corners here to make cleaning or maintenance easier, but removing guards exposes pinch points, nip points, and rotating shafts that can catch clothing, hair, or hands in seconds. Our standard guarding packages include adjustable belt guards, side rails for overhead conveyors, and chain guards that enclose all moving linkages, but some plants swap in flimsy, homemade guards that don’t meet OSHA standards. A recent client in Michigan tried to save money by using wire mesh instead of solid steel guards on their incline belt conveyor, and last quarter, a loose piece of fabric from a batch of textiles got caught in the mesh, pulling a team member’s sleeve into the conveyor and requiring emergency surgery. The fix was simple: we installed the heavy-duty, purpose-built guards we recommend, and they haven’t had an issue since. The other part of guarding is making sure emergency stop (E-stop) buttons are placed where they’re easy to reach in a pinch, and that they’re tested weekly. I always tell clients to place E-stops every 20 feet along horizontal conveyors and within arm’s reach on inclines or turns, and to make sure they’re bright yellow and clearly labeled—if an operator can’t find the E-stop in a split second, it’s useless.

Training is the backbone of conveying equipment safety, and it’s not just a one-day course on day one. When we sell a new conveyor system, we provide on-site training for all the operators, maintenance staff, and supervisors at no extra cost, but I’ve had clients tell me their team thought that meant they knew everything about the machine. The truth is, as conveyors age, new jam types pop up, and new team members are hired, training needs to be ongoing. At a packaging plant that purchased our modular conveyors two years ago, they hold 15-minute safety huddles every Monday where they go over one specific risk with their conveyors—last month, they talked about how to properly clear a roller jam without reaching over the side. They also have a “near-miss” log that anyone can add to, and last quarter, an operator wrote about slipping while trying to reach a jam; the team responded by installing non-slip steps at all high conveyor points, which has prevented three potential falls. The best training I’ve seen isn’t just about rules—it’s about giving staff the power to speak up when something feels unsafe, without fear of being penalized. Too many operators keep quiet about a faulty E-stop or a loose guard because they don’t want to slow down production, but that’s a mindset that gets people hurt.

Proper maintenance is another area where I see lots of gaps, and it’s tied directly to safety. A conveyor that’s worn out, misaligned, or has frayed belts is a hazard waiting to happen. I always recommend clients create a daily checklist for operators to run through before starting their shift: check for loose bolts, inspect belts for tears, make sure guards are secure, and test E-stops. Then, there’s the monthly and annual maintenance that needs to be done by trained technicians. Last year, a metal stamping client of ours skipped their annual conveyor belt tension check, and the belt snapped while it was moving, sending heavy stamped parts sliding into an operator’s station—they missed two days of production, and we had to rush a replacement belt to them at a steep after-hours cost. Now, they have a scheduled maintenance contract with our service team, and we send technicians every three months to do inspections, adjust tension, and replace worn parts before they become a problem. The good news is that modern conveying equipment, like the modular systems we design, has self-diagnostic features that alert you to issues before they cause a breakdown—if your supplier doesn’t offer that, it might be time to upgrade, because safety technology has come a long way in the last few years.

Don’t forget about housekeeping, which sounds simple but makes a huge difference. I’ve been in factories where parts, dust, or packaging material is scattered around conveyor lines, creating tripping hazards and also getting stuck in the conveyor’s moving parts. A client in Illinois had a conveyor jam last year because a pile of loose cardboard got wedged between the belt and the frame, and the operator slipped on a stack of plastic pallets while trying to clear it, breaking their arm. Small things like sweeping debris away from conveyors, storing materials at least three feet from equipment, and cleaning up spills right away aren’t just about keeping the floor neat—they’re about preventing accidents. We also recommend that clients mark clear walkways around all conveying systems, so operators don’t have to step close to moving parts to get from one station to another. If your team is constantly navigating around piles of material near conveyors, that’s a sign that your layout might need to be adjusted for safety, not just efficiency.

There’s one more thing that’s often overlooked when it comes to conveying equipment safety: operator behavior. Even with the best guards, training, and maintenance, humans make mistakes, so we need to design systems that reduce those risks. For example, our conveyors have safety features like auto-shutoff for when guards are opened, so if an operator does need to access a moving part, the machine stops immediately. We also build speed controls that let operators adjust the conveyor’s speed for loading and unloading, which reduces the chance of parts flying off or getting caught. I always tell clients that when we design a custom conveying system for their facility, safety is baked into every step—not something added on as an afterthought. That’s why we work with each client individually, taking measurements of their space, talking to their operators about what’s working and what’s not, and making sure the final system fits their needs as well as their safety requirements.

Now, I know some of you might be reading this and thinking, “We already have safety rules—why do I need to hear this from a conveying equipment supplier?” The truth is, we work with hundreds of facilities every year, so we’ve seen every possible safety misstep, and we want to help you avoid them. If you’re unsure about how your current conveying measures up, or if you’re thinking about upgrading your equipment, we can send a team out to do a free safety assessment of your lines. We’ll point out gaps in guarding, LOTO procedures, training, and maintenance, and give you actionable steps to fix them.

At the end of the day, conveying equipment is meant to make jobs easier, not more dangerous. The clients who take safety seriously—who invest in proper training, maintenance, and the right equipment—are the ones that have the fewest accidents and the most productive teams. If you want to make sure your conveying lines are as safe as they can be, or if you’re in the market for new equipment that puts safety first, reach out to our team to discuss your needs. We’re here to help, and we’re not just selling machines—we’re partnering with you to keep your people safe.

Grain Loading Equipment References

  1. Occupational Safety and Health Administration (OSHA). 29 CFR 1910.212, General Requirements for All Machines. U.S. Department of Labor, 2022.
  2. Conveying Equipment Manufacturers Association (CEMA). Safety Guidelines for Bulk Material Conveying Systems, 7th Edition. CEMA, 2021.
  3. National Institute for Occupational Safety and Health (NIOSH). Preventing Injuries from Conveying Equipment in Manufacturing Settings. NIOSH Publication, 2020.
  4. American National Standards Institute (ANSI). B20.1, Safety Standard for Conveyors and Related Equipment. ANSI, 2023.
  5. Occupational Safety and Health Administration (OSHA). Lockout/Tagout of Energy Sources (LOTO) Standard: 29 CFR 1910.147. U.S. Department of Labor, 2022.

Zhongmao Ruitong Hebei Grain Machinery Manufacturing Co., Ltd.
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