Bulk-handling conveyors are massive, powerful systems that move tons of material per hour in complex networks over long distances. Whether the systems are in a mine, cement plant, port, or quarry, their size, speed, and power present the risk of catastrophic injury in the blink of an eye. This makes training essential, no matter what activity is happening around a conveyor.
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Conveyor drive motors can be as large as 600 HP (450 kW), moving belts as fast as 2000 fpm (10 mps)
Training Challenges
Many industries are facing the retirement of workers with expertise and knowledge, leaving them without adequate mentorship. This has both good and bad aspects. Although basic on-the-job training passed down from worker to worker is valuable, it can leave organizations vulnerable to past workers teaching bad habits.
Unless the operations personnel have solid, real-world knowledge in bulk material handling to make educated decisions when addressing problems, bad habits are easily perpetuated. Knowledge needs to help maintenance workers avoid costly and dangerous trial-and-error learning.
Understanding how and why accidents happen is also critical in preventing them from occurring. Having knowledgeable trainers who address the symptoms of problems with workable long-term solutions will reduce unsafe practices and improve efficiency while enhancing profitability.
Seek Deeper Understanding
In many operations, there is a lack of qualified conveyor trainers. Equipment vendors and third-party trainers can be highly effective sources of training. However, with hundreds of companies providing such services, expertise and approaches can vary widely.
Training specialists from equipment manufacturers who offer training programs like Martin Engineering, focus on overall conveyor performance and safety training. Combining deep industry experience and modern engineering will significantly improve operating decisions, resulting in higher productivity, fewer safety incidents, and reduced unplanned outages.
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BEST PRACTICE: Bulk handling specialists who conduct a site-specific analysis before any training sessions
Qualified teachers should provide a variety of delivery methods based on different learning styles. For example, they should provide good graphics for visual learners, clear documentation for those who learn best by reading, demonstration models, or actual equipment for hands-on learners. These methods should all be designed to increase the probability of measurable positive results.
Copyright 2025 Martin Engineering
Best Practice: Vary learning tools and provide online access to tools that reinforce core lessons
The Payback on Quality Training
Organizations that embrace an effective training culture from the top down show significant performance advantages over the competition. This is reflected in safety, productivity, and environmental records, as well as above-industry-average financial returns and share prices.
While many training efforts aim to maximize productivity, improving safety is a key element in achieving this objective. Insufficient safety training can be incredibly costly to an operation. When companies ensure workers have adequate training on particular risks, costs are minimized. Instead of simply teaching workers how to maintain a conveyor system, educators must also help students understand the consequences of not performing adequate maintenance.
Copyright 2025 Martin Engineering
Best Practice: Learning on new systems can provide insight into how new equipment designs address old persistent problems