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The Importance of Hopper Feeder Safety When Crushing
Crushing machines are built with operator safety in mind, but no design can account for every mistake, oversight, or shortcut. It can be tempting to cut corners to avoid downtime, yet saving a few minutes could lead to serious injury or death.
The hopper feeder carries some of the greatest risk on the site, since heavy trucks dump large loads of hard material into it, and a single lapse in attention there can have immediate, severe consequences.
Here, we walk through the key crushing safety recommendations every operator needs to know to keep their team safe.
Staying Vigilant at the Hopper
One of the more proactive choices that any safety-conscientious operator can make to reduce risk is to remain vigilant. When operating stone crushing equipment or vehicles for depositing material, like rocks or concrete, into the hopper feeder, take time to assess the area for any potential issues, like workers too close to equipment or obstructions in the hopper feeder itself.
To prevent obstructions, the general size of each rock being fed into the hopper feeder needs to be assessed. It’s recommended that any materials being fed into the hopper feeder should be at most 80% the size of the crusher opening into which the feeder processes material, often referred to as the F80 rule.
Keeping Hands and Focus Off Moving Material
As material is being processed, it’s unequivocally advised that plant operators should never attempt to pick out material as it flows through the hopper. This kind of irresponsible activity, from the operator’s platform or on top of the crusher, is a serious breach of safety and could result in serious injury or death.
Responding to Obstructions Safely
Should an obstruction occur in the hopper feeder, follow these steps:
- Shut down the crusher plant and follow proper lock-out-tag-out procedures as soon as possible, without creating any additional safety issues.
- Wait for the crusher to totally stop. This prevents injury to the crusher and its operators as the obstruction is removed.
- Assess the obstruction to determine which material needs to be removed.
- Attempt to remove the obstruction by mechanical means first.
- If the material cannot be removed mechanically, have it removed manually, and only by someone who has been competently trained.
Regular hopper feeder maintenance can also reduce the chances of obstructions forming in the first place.
Why a Spotter Matters
Whenever you’re operating industrial crushing equipment or addressing safety concerns, it’s always best to have a spotter to watch for any emerging issues. Remember, saving lives is more important than saving time.
Following safety protocol is in the best interest of everyone involved, so please take time to be mindful and to be safe. Other site hazards, like airborne material, deserve the same attention. Our guide to dealing with dust around portable crushing plants covers those risks in more detail.
Disclaimer: This article does not serve as an official safety recommendation by Eagle Crusher and should not be viewed as such. All relevant staff should consult their owner’s manual before operating Eagle Crusher equipment, or any other manufacturer’s equipment, and comply with the safety guidelines therein.
Get More Crushing Safety Recommendations
Hopper feeder safety starts with the habits your crew builds every day. Review these recommendations with your team, and contact Eagle Crusher to speak with a Team Eagle representative about safety-minded equipment and support for your operation.