Conveyors are the workhorses of modern material handling operations. From grain facilities to manufacturing floors, a well-designed conveyor system moves product efficiently and reliably. However, without proper safety practices in place, conveyors can also present serious hazards to employees. At KC Supply Co., we know that safety and productivity go hand in hand. A safe conveyor system is a reliable conveyor system and one that protects your team and keeps your operation running smoothly.

Here’s a practical guide to key conveyor system safety tips that every business should implement.

1. Conduct Regular Inspections

Routine inspections are the cornerstone of a safe conveyor setup. A conveyor system includes moving parts, pinch points, and electrical components—any of which can wear over time or become damaged. Establish a regular inspection schedule to check for:

  • Loose or worn belts

  • Misaligned rollers and pulleys

  • Damaged guards or safety covers

  • Signs of excessive wear on bearings and chains

Identifying issues early helps prevent unexpected breakdowns and reduces the risk of accidents.

2. Install Proper Guarding

One of the most effective ways to protect workers around a conveyor system is through appropriate guarding. Guards prevent hands, clothing, and tools from getting caught in moving parts. Ensure that all:

  • Nip points

  • Sheaves

  • Uncovered rollers

  • Exposed chains

are protected with guards that meet industry safety standards. Never bypass or remove guards for convenience. If maintenance access is needed, use lockable guard panels that can only be opened by authorized personnel.

3. Provide Clear Signage

Visual warnings and labels are critical for conveyor system safety. Strategically place signs that alert workers to:

  • Moving parts

  • Restricted areas

  • High voltage

  • Possible pinch points

Clear, visible signage helps ensure that both seasoned employees and temporary workers are aware of potential hazards.

4. Train Employees Thoroughly

A well-trained workforce is a safe workforce. Conveyor system safety training should cover:

  • Proper startup and shutdown procedures

  • How to recognize hazards

  • Emergency stop locations and use

  • Lockout/tagout protocols

  • Safe loading and unloading practices

Training shouldn’t be a one-time event. Regular refreshers help reinforce safe habits and keep safety top-of-mind.

5. Implement Lockout/Tagout Procedures

Maintenance and repair work on a conveyor system must be done with energy sources fully isolated. Lockout/tagout procedures ensure that machinery cannot be accidentally energized while someone is servicing it. Make sure that:

  • Only authorized personnel perform lockout/tagout

  • Procedures are documented and standardized

  • Proper locks and tags are used every time

This reduces the risk of injuries caused by unexpected startups.

6. Keep Work Areas Clean and Organized

Cluttered workspaces, spilled materials, or tools left near conveyors can increase the risk of slips, trips, and accidental contact with moving parts. Maintain clear walkways and remove debris promptly. Keep the area around the conveyor system free from obstacles so employees can move safely when loading, inspecting, or troubleshooting.

7. Use Emergency Stop Devices

Emergency stop devices (E-Stops) are essential safety features. They allow workers to shut down the conveyor system immediately if a dangerous condition arises. Place E-Stops in easily accessible locations along the conveyor path and test them regularly to ensure they function properly.

8. Maintain Adequate Lighting

Good lighting is often overlooked but plays a major role in conveyor safety. Adequate illumination helps workers:

  • See potential hazards

  • Read controls and indicators clearly

  • Perform inspections and maintenance safely

Evaluate your facility’s lighting and upgrade where necessary to improve visibility around the conveyor system.

9. Encourage Reporting and Feedback

Safety is a team effort. Encourage workers to report any unsafe conditions, unusual noises, or irregular conveyor behavior. Establish a culture where employees feel comfortable bringing up safety concerns without fear of reprisal. This kind of proactive communication helps catch issues early and builds a stronger, safer workplace.

Conclusion

A conveyor system can greatly enhance productivity—but only if it’s operated with safety at the forefront. From regular inspections and employee training to proper guarding and emergency measures, putting these conveyor system safety tips into practice will help protect your team and your investment.

At KC Supply Co., we’re committed to helping you run safe and efficient material handling operations. Contact us for expert guidance on conveyor systems, safety equipment, and best practices tailored to your facility’s needs.