Enhancing Workplace Safety – The Role of Conveyor Systems

In today’s hectic industrial landscape, workplace safety remains a top priority. Across manufacturing, logistics, and production environments, businesses are seeking out different technologies that will provide efficient and effective ways of reducing the potential risk of injury to their workforce while maintaining operational efficiency and productivity.

One vital component in this effort is the conveyor system, a technology that not only boosts operational efficiency but also plays a critical role in improving workplace safety through proper safety measures and risk controls.

Types of Conveyor Systems

There are many different types of conveyors used for material handling activities within logistics, manufacturing, and production facilities, each with their own unique features and benefits. Some of the main types of conveyor systems widely used today include:

Belt Conveyor Range DHL Tewksbury

a conveyor as a conveyor systems warehouse

roller conveyor

Belt Conveyors

Best for: General material handling.

Features: Flat or troughed belt; good for horizontal and inclined movement.

Benefits: Belt conveyors are reliable, easy to maintain, low operational noise. These belt conveyor systems must adhere to the requirements of belt conveyors including safety divides and protective equipment.

Roller Conveyors (Gravity or Powered)

Best for: Moving boxed or rigid items.

Features: Can be manually operated (gravity) or motorised.

Benefits: Low cost and minimal maintenance for light to medium loads. Roller conveyor safety considerations include clear conveyor safety rules and proper conveyor guards.

Chain Conveyors

Best for: Heavy-duty items such as pallets or automotive parts.

Features: Uses chains to drive movement.

Benefits: Chain Conveyors are durable and capable of handling extreme loads and heavy loads safely with effective measures in place.

Overhead Conveyors

Best for: Items that hang during transport (e.g., garments or car doors).

Features: Suspended track systems.

Benefits: Saves floor space and is ideal for assembly operations while reducing safety risks from floor-level congestion.

Screw Conveyors

Best for: Semi-solid materials like grains, powders, or food waste.

Features: Rotating helical screw inside a tube.

Benefits: Enclosed system prevents spills and contamination and supports safer handling of bulk material.

Pneumatic Conveyors

Best for: Lightweight materials in bulk (e.g., flour or plastic pellets).

Features: Moves material using air pressure.

Benefits: Fast and enclosed for safe, dust-free transport that minimises unsafe conditions.

Even with so many types of conveyor systems available, they all have one thing in common: a design with safety in mind to ensure safe operations.

The Importance of Conveyor Systems with Integrated Safety

According to the Health and Safety Executive (HSE), there were 561,000 non-fatal injuries reported by UK workers in 2022/23, with a significant number occurring in warehousing and manufacturing sectors. Manual handling remains one of the top causes of workplace injury, often from repetitive tasks or heavy lifting. Conveyor systems are designed to help minimise this risk by reducing the need for workers to lift, carry, or move heavy or awkward loads manually, thus addressing common hazards.

Conveyor Safety Measures: Protecting People and Processes

Modern conveyor systems have been the beneficiary of enhanced engineering over the years, now providing a highly efficient combination of streamlined material handling with considerable safety features as standard. Some of the key conveyor safety tips and features include:

Emergency stop buttons placed strategically along conveyor lines.
Conveyor guards and covers to prevent operator contact with moving parts.
Interlocking mechanisms to shut down the conveyor when a hazard is detected.
Conveyor controls and speed limiters to prevent unsafe conditions.
Visible warning systems and audible warning signals to alert staff of changes.
Automatic load detection systems to monitor load capacity and avoid overloading.

Implementing these features supports safe operations and helps reduce conveyor belt accidents and injuries from tasks on conveyor belts.

Ergonomic Conveyor Design: Taking a Preventative Approach

Going beyond traditional safety features, today’s conveyor designs consider ergonomics, with a focus on minimising physical strain and repetitive motion injuries. Key ergonomic enhancements include:

Height-adjustable systems for standing or seated use.

Angled or curved systems to reduce reaching and twisting.

Low-noise operation for improved auditory safety.

Automated diverters and safety divides for less manual handling.

Tailored solutions such as L-A-C’s Lift-Up Gate improve access and reduce safety risks by allowing controlled passage through conveyor loops.

Industry Applications of Conveyor Systems

Conveyor systems have long supported efficient, safe, and automated handling across a wide range of sectors:

Manufacturing

Improving flow between assembly stages and lowering injury rates through safe operation of conveyors.

Warehousing & Logistics

Used in sorting and order fulfilment with reduced risk due to automated movement and safety measures.

Automotive

Enabling efficient delivery of components to workstations while reducing manual tasks.

Food & Beverage

Upholding hygiene and safe practices through enclosed belt conveyor systems and protective equipment.

Mining & Quarrying

Handling bulk products while minimising physical strain and enhancing worker protection.

Creating a Safety-First Future

As UK industries strive for minimal risk workplaces, conveyor system safety continues to be integral to both operational performance and health & safety strategies. Employers can ensure compliance with safety requirements and protect workers through regular maintenance, a proactive conveyor assessment schedule, and ongoing monitoring of maintenance records.

Investing in the right conveyor technology is not just about throughput and efficiency—it’s about keeping people safe. By following conveyor safety rules, maintaining proper safety measures, and implementing a strong training program supported by relevant training materials, businesses can create safer work environments. Whether it’s reducing risks related to power sources, ensuring workers wear safety shoes, or maintaining the system on a regular basis, effective conveyor maintenance and control devices help build a secure, scalable operation that meets today’s workplace safety expectations.