Conveyor Safety Protocols: Top Guidelines for Industrial Worksites
Conveyor systems are essential in manufacturing, mining, and warehouse environments—but they also pose serious risks when not operated properly. This guide outlines essential safety protocols for anyone working with or around conveyors, helping reduce accidents and meet compliance standards such as OSHA and ANSI.
1. Pre-Operation Safety Checklist
Before starting a conveyor:
- Inspect all guards, emergency stops, pull cords, and warning devices.
- Check belt tension, alignment, and the condition of rollers and chutes.
- Clear debris and ensure proper lubrication of moving parts.
- Lockout/Tagout (LOTO) must be verified before any inspection or maintenance begins.
Tip: Use a standardized checklist for daily inspections to catch issues early.
2. Only Trained Personnel Allowed
- Conveyor systems should be operated and maintained only by trained and authorized staff.
- Training must cover:
- Safe start-up and shutdown procedures
- Recognizing nip points and pinch hazards
- Emergency response steps
Suggestion: Document refresher training and provide onboarding manuals for new employees.
3. Mandatory Personal Protective Equipment (PPE)
All personnel must wear:
- Helmets, safety gloves, and steel-toe footwear
- Eye and hearing protection
- High-visibility vests in high-traffic zones
4. Safe Operating Practices
- Never ride, climb, or sit on conveyors.
- Do not reach into moving parts or under guarding.
- Use walkways and marked crossovers.
- Stay clear of nip points and keep clothing/hair secured.
- Emergency stop cords must be functional and within reach at all times.
5. Emergency Stop & Lockout Protocols
- LOTO must be in place before cleaning, repairs, or adjustments.
- Emergency mechanisms should:
- Be visible and clearly marked
- Be tested regularly
- Stop the system immediately when activated
6. Housekeeping & Environmental Safety
- Remove oil, dust, and debris from the area daily.
- Maintain adequate lighting and airflow.
- Avoid leaving tools or equipment on or near conveyor pathways.
7. Routine Maintenance & Inspections
- Inspect pulleys, belts, guards, and tracking systems regularly.
- Use only approved tools following Standard Operating Procedures (SOPs).
- Log every maintenance and inspection in official records.
Pro Tip: Weekly inspection reports help identify patterns and recurring issues.
8. Hazard Warnings & Communication
- Install signage at:
- Pinch points and rotating parts
- Drive assemblies
- Emergency zones
- Announce downtime, repairs, or changes via radio or posted notices.
9. Safety in Automated Conveyor Systems
- Use safety interlocks and mechanical guards.
- Ensure that start-up alarms (auditory and visual) are functional and tested regularly.
10. Incident Response and Drills
- Conduct and document emergency response drills quarterly.
- Encourage staff to report near misses or unsafe behavior immediately.