Conveyor belt hazards are hazards associated with the use of the conveyor belt.
Recall that a conveyor belt is a belt that has been looped and is wound around one or more pulleys for driving. The conveyor belt is supported by rollers or a metal plate bed and is driven by an electric motor. There is an idler pulley that is not driven and a driving pulley that drives a conveyor belt.
On a conveyor belt, pulley drives at the infeed end are called tail drives, and those at the discharge end are called head drives.
There are two (2) types of conveyor belt:
- Roller Bed Conveyor Belt: The surface of a roller bed conveyor belt consists of a set of rollers chosen to meet the needs of production requirements, such as speed, weight, and the type of products being moved.
- Flat Belt Conveyor Belt: A flat belt conveyor belt uses a series of pulleys to move materials and supplies. Its belt is made of natural or synthetic materials; this makes it versatile and adaptable to varying conditions and applications.
Conveyor Belt Hazards
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Entanglement Hazards: Loose clothing, hair, jewelry, or even tools can become caught in the moving parts of a conveyor belt. Once caught, the speed and force of the belt can pull a worker into the mechanism in seconds, leading to serious injuries such as fractures, amputations, or fatalities. These hazards are especially high near nip points and rotating shafts. Workers must wear appropriate, fitted clothing, secure long hair, and avoid carrying loose objects near operating conveyors to prevent entanglement incidents.
2. Pinch Point Injuries: Pinch points occur where the belt meets pulleys, rollers, or other moving parts. If a worker’s hand, finger, or body part gets trapped between these moving parts, crushing or amputation can occur almost instantly. These areas are often overlooked because they seem small, but they present a significant danger during maintenance or cleaning. Installing guards and lockout/tagout (LOTO) procedures before working on or near pinch points is essential to avoid serious harm.
3. Falling Material Hazards: Conveyor belts often carry heavy loads such as rocks, boxes, or bulk materials. If the load is not properly secured or if the belt is overloaded, materials can fall from the belt, posing a risk of head, back, or foot injuries to workers below. This hazard is particularly high in overhead conveyors or inclined belts. Workers should wear hard hats in these areas, and conveyors should have proper side guards or catch trays to prevent falling debris.
4. Shear Point Hazards: Shear points occur when the moving belt passes closely by a stationary object, creating a cutting or shearing effect. These points can trap and severely injure hands, fingers, or other body parts if they enter the area. Even a brief contact can result in deep lacerations or amputations. Proper guarding, signage, and safe distance rules are necessary to protect workers from these dangerous areas of a conveyor system.
5. Slips, Trips, and Falls: Conveyor belts can contribute to slip, trip, and fall hazards if spilled materials, grease, or debris accumulate on walkways. Workers who lose balance near a moving belt risk falling onto or under the conveyor. Elevated conveyors pose an additional danger because a fall from height can cause severe injuries. Regular housekeeping, installing non-slip surfaces, and maintaining clear walkways are critical preventive measures.
6. Caught-in/Between Hazards: This occurs when a worker is trapped between the conveyor belt and another object, such as a wall, structure, or another piece of equipment. The force of the belt can crush the worker before they can react. These incidents often happen during maintenance, when workers attempt to remove jams without turning the system off. LOTO procedures and awareness training are vital in preventing caught-in/between injuries.
7. Electrical Hazards: Conveyor belts are powered by electric motors, and faults in wiring, controls, or grounding can lead to shocks or electrocution. Wet environments or damaged insulation further increase the risk. Workers performing repairs or inspections should follow electrical safety protocols and ensure equipment is de-energized before handling. Proper grounding, regular inspection, and using only trained personnel for electrical work help minimize these dangers.
8. Fire Hazards: Friction from misaligned belts, overheated motors, or flammable materials on the belt can lead to fires. Conveyor belts made from certain materials may also be highly flammable. Fires can spread quickly along the length of the conveyor, especially in enclosed spaces such as tunnels or buildings. Installing temperature sensors, using flame-resistant belt materials, and performing routine maintenance are effective ways to prevent conveyor-related fires.
9. Noise Hazards: Conveyor systems can generate high noise levels due to motor operation, belt movement, and material handling. Prolonged exposure to such noise without hearing protection can lead to permanent hearing damage. In addition, loud environments make it harder for workers to hear warning signals or communicate, increasing the risk of accidents. Regular noise monitoring, installing sound barriers, and providing hearing protection are necessary to protect workers’ hearing.
10. Manual Handling and Ergonomic Hazards: Although conveyors are designed to reduce manual lifting, workers still need to load, unload, or adjust materials, which can lead to strains, sprains, or repetitive motion injuries. Poor conveyor height or awkward positioning can force workers into unnatural postures, increasing the risk of musculoskeletal disorders. Adjusting conveyor height, automating loading/unloading, and training workers on safe lifting techniques can significantly reduce ergonomic hazards.
Conveyor Belt Safety Tips
Here are some safety tips you should follow when working with a conveyor belt;
- Wear a hard hat and safety shoes.
- Tie back (and tuck in) long hair.
- Know the location of the emergency “shut-off” devices and how to use them.
- Make sure all safeguards and guards, including cages, barriers, guardrails, warning signals, and other safety devices that are required, are in place and operational.
- Know how to work near machinery safely.
- Do not wear loose clothing or jewelry.
- Do not climb, step, sit, or ride on the conveyors.
- Do not alter or remove guards or safety devices.
- Do not try to remove stuck items or debris until the conveyor is locked out.
- Do not service the conveyor without following lock-out procedures.
Conclusion
Knowing the Conveyor Belt Hazards is the first point of call if you must work safely around a conveyor belt. In this blog post, we have highlighted major hazards associated with the use of conveyor belts and some precautions to follow.
Follow these precautions to stay safe when working with or around a conveyor belt.
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