Start with the actual product envelope
The smallest product, largest gap, overhang, conveyor height and possible product absence all affect the opening.
- Measure product and pallet variations
- Consider reversing and accumulation
- Review empty-conveyor conditions
Map reach routes—not just the straight line
People may reach over, under, around or between loads, and may climb or lean into an opening.
- Review side and underside access
- Consider adjacent platforms and structures
- Control reach to both conveyor and downstream machinery
Use physical geometry wherever practical
Tunnels, baffles, infill panels and internal guards can provide robust reach prevention.
- Retain access for cleaning and jam recovery
- Avoid new trapping points
- Make removable sections tool-controlled or monitored as required
Design muting as a complete sequence
Where a protective device is muted for product flow, sensor order, direction, time, fault behaviour and status indication matter.
- Differentiate product from person entry
- Limit the muted condition
- Test interrupted and incorrect sequences
Apply the guidance to the specific machine.
This guide supports early decision-making but does not replace a project-specific risk assessment, safety-system design or validation. Machine condition, tasks, controls and modification scope can change the correct solution.
Questions
Direct answers.
Is a conveyor opening automatically safe if it is small?+
No. Safety depends on the opening, distance to the hazard, reach route and whether a person can enlarge or bypass the route.
What is a guard tunnel?+
A tunnel extends the guarded path so the opening remains far enough from hazardous parts while allowing product flow.
Can light curtains be muted for pallet transfer?+
Potentially, using a properly designed sensor sequence and physical arrangement that controls person entry during the muted condition.
