Conveyor Operation SWMS

Conveyors are ubiquitous in manufacturing facilities and present nip point entrapment hazards at every roller, pulley, and belt junction. Workers have been killed and severely injured by being drawn into in-running nip points while attempting to clear jams, clean belts, or retrieve fallen products during conveyor operation. The speed and force of conveyor systems means that once entrapment begins, the worker cannot self-rescue. Emergency stop systems, guarding of in-running nip points, and lockout tagout procedures for cleaning and maintenance are the critical controls. This template maps controls to the binding Managing Risks of Plant Code of Practice effective 1 July 2026.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.7 — Plant

hrcw category

Plant with entrapment risk

code of practice

Managing Risks of Plant in the Workplace (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Entrapment at in-running nip points between belt and rollers	Amputation, crush injuries, death	Possible
Entrapment in screw conveyor auger	Severe laceration, amputation, death	Unlikely
Struck by product falling from elevated conveyor sections	Head injuries, fractures	Possible
Clothing or body part drawn into unguarded tail pulley	Entanglement, amputation, death	Possible
Jam clearing while conveyor is running	Hand entrapment, amputation	Possible
Falls from elevated conveyor walkways during maintenance	Fractures, head injuries	Possible

Controls (Hierarchy of Controls)

Guard all in-running nip points at head and tail pulleys, drive rollers, and snub rollers

Install emergency stop pull-cords along the full length of all conveyor sections within worker reach

Lockout and tagout conveyors before any cleaning, jam clearing, or maintenance work

Enclose screw conveyors to prevent access to the rotating auger during operation

Install guards and toe boards on elevated conveyor sections to prevent objects falling onto workers below

Prohibit reaching into running conveyors to clear jams or retrieve products

Conduct pre-start inspections of guards, emergency stops, and belt condition before each shift

Test emergency stop pull-cords at defined intervals to verify they stop the conveyor within acceptable distance

Recent Prosecutions

SafeWork SA prosecution$840,000

Worker killed in manufacturing equipment entrapment with inadequate guarding and isolation procedures.

2024 — SafeWork SA Manufacturing Prosecution [2024]

Orica Australia Pty Ltd$1,200,000

Multiple plant safety failures in industrial operations.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

What Your SWMS Must Include

✓Nip point guard register for every conveyor in the facility

✓Emergency stop pull-cord location map and testing schedule

✓Lockout tagout procedure specific to each conveyor system

✓Jam clearing procedure requiring conveyor shutdown before intervention

✓Pre-start inspection checklist for guards, e-stops, and belt condition

Need a compliant Conveyor Operation SWMS?

Our WHS consultants build conveyor-specific SWMS that address nip point guarding, emergency stops, and LOTO for your conveyor systems.