Conveyors help move products quickly through warehouses. They save time and reduce heavy lifting. But if not used safely, conveyors can be dangerous, especially for pickers and packers who work near them every day.
This guide explains the basics of conveyor safety. You’ll learn how to spot hazards, dress correctly, and respond in emergencies.
Why Conveyor Safety Matters
Thousands of workers are injured each year because of conveyor systems. Many injuries involve hands, fingers, arms, hair, or clothing getting caught in moving parts.
Some accidents even lead to serious injuries like broken bones, amputations, or worse. Most of these incidents happen during normal tasks like loading, unloading, or clearing a jam.
Knowing how to work safely around conveyors can protect you and your coworkers.
Common Conveyor Hazards
Conveyor systems have several moving parts. Some can be dangerous if you don’t stay alert.
1. Pinch Points
Pinch points are places where parts of the conveyor meet or move past each other. Fingers, hands, or clothing can get caught between rollers, belts, and gears.
Watch out for:
- Rollers that rotate
- Moving belts that pass over pulleys
- Chains or sprockets that are exposed
Always keep body parts and loose items away from these areas.
2. Loose Clothing and Jewelry
Baggy clothes, long sleeves, and jewelry can get pulled into the conveyor. This can cause serious injuries in seconds.
Avoid wearing:
- Long necklaces or dangling bracelets
- Untucked shirts or hoodies with strings
- Loose gloves that can catch on equipment
Tie back long hair and wear close-fitting clothes. Use PPE (personal protective equipment) that’s designed for warehouse work.
3. Unstable Loads
If a box or product is not placed correctly on the conveyor, it might fall off. This could hit someone or cause a tripping hazard.
Stack items neatly and make sure they are balanced. Avoid overloading the conveyor, as this can cause jams or spills.
4. Emergency Stops
All conveyors should have emergency stop buttons or pull cords. These stop the system immediately if something goes wrong.
Know where these emergency stops are located along the line. Don’t block them with boxes, carts, or other items.
Safe Behavior Near Conveyors
A few daily habits can make a big difference in conveyor safety.
Stay Alert
Pay attention while working. Most injuries happen when people are distracted or in a rush.
Don’t:
- Use your phone while near the conveyor
- Joke around or push others
- Reach into the moving parts
Always stay focused on the task.
Keep Clear of Moving Parts
Never try to clear a jam while the conveyor is running. Wait until it has fully stopped.
Also, avoid climbing, sitting, or standing on a conveyor, even if it’s not moving. It could start without warning.
Use Tools, Not Hands
If something gets stuck or needs adjustment, use a tool, not your hands. If possible, ask a supervisor or maintenance staff for help.
Never bypass machine guards or safety devices. They are there to protect you.
What To Do in Case of Emergency
Use the Stop Button
If someone is hurt, clothing is caught, or something looks wrong, press the emergency stop button right away. You don’t need permission. Safety comes first.
Report the Problem
Tell your supervisor immediately after using the stop. They need to inspect the system before restarting it.
If you spot something dangerous, like exposed wiring or a missing guard, report it, even if no one is hurt.
First Aid
If someone is injured:
- Call for medical help
- Don’t move them unless they are in more danger by staying
- If trained, give first aid while help is on the way
Quick action can save lives.
Conveyor Safety During Maintenance
Most accidents happen during cleaning, repairs, or maintenance. If you ever assist with this work, keep these rules in mind:
- Shut down the conveyor fully and disconnect the power
- Use lockout/tagout procedures so the system can’t restart unexpectedly
- Don’t remove guards or panels unless trained and authorized
- Keep tools and parts away from moving belts and rollers
Only qualified workers should perform maintenance. If you’re not sure, ask first.
Safety Tips Recap
Here’s a quick checklist every picker and packer should follow:
- Wear tight-fitting clothes and remove jewelry
- Tie back long hair
- Stay focused, no distractions
- Never reach into moving parts
- Know where emergency stops are
- Report problems right away
- Never ride or stand on a conveyor
- Keep aisles and emergency access areas clear
Real-Life Incident Example
A 27-year-old warehouse worker was pulling a small package off a moving conveyor. His glove got caught in the roller, pulling his hand in. He suffered severe injuries and required surgery.
Later, it was found he had been wearing loose gloves, and the machine’s guard was removed for cleaning but never put back.
This accident could have been prevented with the right gear and regular equipment checks.
Training and Supervision Matter
Warehouses should provide safety training to all new workers. If you haven’t received it, ask your supervisor. Ongoing training helps you stay updated on safety practices.
Supervisors should also do regular walk-throughs to check for blocked emergency stops, missing guards, or unsafe behavior.
You play a role, too. Speak up if you see something unsafe.
Final Thoughts
Conveyors are useful but can be dangerous if you’re not careful. The good news? Most conveyor injuries can be avoided by following simple safety steps.
Pay attention to your surroundings, wear proper gear, and don’t take shortcuts. Safety isn’t just your manager’s job, it starts with you.
If you follow the tips in this guide, you can help create a safer, smarter warehouse for yourself and your team.
