Conveyor systems are a necessity in many industries, ranging from agriculture to food production. While these belts are important for manufacturing, moving and processing products, and more, they can become quite dangerous if proper safety measures are not taken. In fact, the Bureau of Labor Statistics (BLS) reports that nearly 9,000 workers are injured each year in conveyor belt accidents.
Fortunately, there are ways to prevent workplace accidents and injuries associated with conveyors, as long as the proper measures are taken. Consider the following tips for practicing conveyor safety to ensure your manufacturing environment is up to standard.
Types of Conveyors to Consider
Before diving into our conveyor safety tips and tricks, we first must consider which types of conveyor belts can cause workplace injuries. While all belts have risks associated with usage, there are a few select options we like to focus on.
Drag Chain Conveyors
Drag chain conveyors use several components to move products and materials. These include scrapers, chains, drive units, troughs, and flights. Materials are pulled along the conveyor by flights that are attached to the chains, allowing goods to be dragged appropriately.
Key advantages of drag chain conveyors include their ability to work reliably even in harsh environments, handle heavy loads, and accommodate various material sizes.
Bucket Conveyors
Bucket conveyors, also called bucket elevators, are often used in the agriculture industry to move materials like grain for processing. The bucket itself works like a scoop, collecting material as it moves along a belt or chain. The material is then moved over a distance and deposited where needed.
Conveyor buckets can be custom-designed to fit certain specifications and requirements. They offer the advantage of a large load capacity, ease of replacement, customization, and more.
Screw Conveyors
Screw conveying systems use a rotating screw shaft to move materials through a trough. The screw shaft rotates accordingly, allowing the material to be moved vertically, horizontally, or along an inclined path.
Screw conveyors can either push or pull materials, depending on which workflow is needed. Pushing screw conveyors are not always the preferred choice for these systems; instead, many industries rely on pulling screw conveyors, as they provide more strength and durability.
Roller Conveyors
This pallet conveying system uses rollers that are supported within a frame, allowing for goods to be moved along the belt. The type of roller conveying system will determine how the products are moved—either by gravity, power, or manually.
Types of roller conveyor systems include:
- Chain-Driven Power Roller Systems: The rollers in these systems are driven by chains to move heavy loads.
- Gravity Roller Systems: These conveyors rely on gravity for pallet handling, which works well for lighter loads that can be pushed manually.
Conveyor-Specific Safety Tips
Conveyor safety practices can depend on the type of system, which is why it’s important to know the distinction between each one.
Safety Tips for Drag Chain & Bucket Conveyors
- Operate at Correct Speeds: Never operate these conveying systems at the wrong speed. These conveyors are made to handle only certain load types with the correct speed in mind.
- Ensure Hardware Isn’t Loose: Hardware on buckets or drag chain conveyors can quickly lead to a malfunctioning system, increasing the risk of injury or accidents.
- Close Covers: These conveyor systems should not be operated unless all covers and guards are securely closed. Only open these covers for inspection, maintenance, or cleaning if the power to the conveyor is off and the system itself is locked out.
- Use Fencing or Railing: For conveyor systems that need open housing, fencing or railing must be installed around the system.
- Use Access Doors: To access conveyor systems (after they have been turned off and locked out), use access doors accordingly. When the system is in use, these doors should be shut and locked.
- Use Sight Panels: To have visibility of the product without sacrificing safety, it’s important to use sight glasses or panels. This ensures quality and efficiency without accident risk.
Safety Tips for Screw Conveyors
Screw conveyors use large augers to move products and materials. Because of their large size, they can do incredible amounts of damage if improperly operated. For example, screw augers used in the grain industry are commonly found at the base of silos. This is a high-risk location for injuries, especially if workers try to unjam the auger without turning it off.
Plastic injection molding is another instance when screw augers are used, which introduces a heating element that makes safety important. Skin burns or burns from splattering plastic or vapors can easily occur from contact with heated barrels. Using correct personal protective equipment is vital.
For these systems, use the right product at the correct speeds. Keep viscosity, or friction, in mind, and make sure to find the right flighting. All of these safety measures work together to ensure these augers do not jam up.
Safety Tips for Roller Conveyors
Roller conveyors are often used in package handling. Because they may rely on gravity or a manual push to move products, they can easily create safety risks. Body parts, loose clothing, or jewelry may become caught in between the rollers.
Consider these tips for roller conveyor safety:
- Use guards and sidewalls to prevent any contact with moving parts.
- Install warning systems to signal when the conveyor starts or stops.
- Install emergency stops, such as pull cords, to ensure the system is immediately shut down if injury is to occur.
- Avoid climbing, stepping, sitting, or riding on the conveyor system.
- Do not overload the conveyor beyond the capacity they can handle.
- Ensure the conveyor is locked out and power has been turned off before performing maintenance.
Other General Tips for Practicing Conveyor Safety
In addition to the above, it’s important to consider other general conveyor safety tips to ensure workers’ safety and the efficiency of your manufacturing processes.
- Ensure Bearing Lubrication: Using the right bearing lubrication ensures safety as the conveyor is in motion. Loose bearings that are not properly lubricated will start to vibrate, causing overheating.
- Turn Off the Power: We’ve said it before, but we’ll say it again—ALWAYS ensure the power is off before performing maintenance or repairs on the conveyor system. The power should be completely disconnected by locking out the energy at the source. We recommend having the same person connect and disconnect the power to ensure consistency and safety.
- Never Cross a Moving Conveyor: When the conveyor system is in motion, never cross over it except at suitable cross points. These should include practical crossing facilities at specific locations. We recommend placing crossings near conveyor controls, as long as height allows.
- Establish Standard Procedures: Ensure proper safety policies are in place, and that all workers have been trained on these procedures. Offer continual training as procedures evolve or change.
By following these conveyor system safety tips, you can avoid workplace accidents and ensure that safety is always upheld above all else.
At IBT Industrial Solutions, our Conveyor Systems and Services Division provides high-quality solutions tailored to your needs. We can evaluate your operations, design a conveyor system, and implement it in your manufacturing processes.
Contact IBT today to learn more.
