Conveyor systems are integral to modern industry, streamlining processes across various sectors. However, when design flaws or safety oversights occur, the consequences can be severe. Below are five real-world conveyor accidents that underscore the importance of robust design and safety protocols.
1. Fatal Entanglement Due to Inadequate Guarding
In March 2023, a worker at Lemitech Pty Ltd, a chicken farm in Lethbridge, Australia, tragically lost his life after becoming entangled in a conveyor belt. Investigations revealed that essential safety components, such as fixed and nip guards, were absent, and a maintenance jog function was not installed. The company faced charges under the Occupational Health and Safety Act for failing to provide a safe workplace.
2. Lack of Lockout/Tagout Procedures Leads to Injury
In April 2021, an employee at a warehouse and storage facility was preparing to inspect a conveyor belt when she noticed a large piece of plastic under the belt. Although she turned off the machine, she did not apply her lock to the lockout switch. This oversight led to the conveyor starting unexpectedly, resulting in the employee sustaining injuries.
This incident highlights the critical importance of adhering to lockout/tagout (LOTO) procedures to ensure machinery remains de-energized during maintenance.
3. Improper Maintenance Causes Severe Injury
In October 2021, an employee was inspecting the conveyor snubber roller when he removed a section of the belly pan while the conveyor was still operational. His hand became caught between the snubber roller and the belt, leading to crushing injuries that required hospitalization.
Proper maintenance protocols and ensuring machinery is powered down during inspections are vital to prevent such accidents.
4. Conveyor Belt Jam Results in Fatality
On September 22, 2020, an employee attempting to locate boxes of frozen foods wedged in a conveyor belt became caught in the belt and was killed, most likely from asphyxiation.
5. Conveyor Crushing Injury at Hailiang Copper Texas
In March 2024, a worker at Hailiang Copper Texas Inc. suffered a severe injury when his right hand became caught between a conveyor belt and a rack holding 15 one-ton copper coils. The employee was attempting to remove debris when the incident occurred, resulting in serious injuries. OSHA’s investigation revealed that the company failed to implement proper safety measures, including the absence of safety guards and inadequate lockout/tagout procedures.
In situations like these, a legal trial witness may be called on to testify in a conveyor accident, providing expert analysis on whether safety standards were met and identifying potential design flaws.
Conclusion: Prioritizing Safety in Conveyor System Design
These incidents highlight the critical need for comprehensive safety measures in conveyor system design and operation. Ensuring proper guarding, adhering to LOTO procedures, conducting regular maintenance, and addressing noise hazards are not just regulatory requirements—they are essential steps to protect workers’ lives and well-being.