How Fast Is Too Fast? Understanding Conveyor Speed Limits for Safety Under EN 619:2022

Why moving pallets faster than allowed can cause more than just accidents—and how EN 619 tells you exactly when to slow down?

In automated facilities and warehouses, speed equals productivity. But when it comes to unit load conveyors, speed can also mean serious injury—especially when loads are heavy, overhanging, or close to people.

That’s why the European safety standard EN 619:2022 includes a special clause to define how fast your conveyor can safely move depending on where it is, what it carries, and how it operates.

Let’s break down Clause 4.2.1.2 – Maximum speed for risk due to movement of unit loads, using plain language, tables, and real-world examples.

What Does Clause 4.2.1.2 Say?

Clause 4.2.1.2 of EN 619:2022 sets maximum conveyor speed limits to reduce the risk of injury if someone contacts a moving load.

This clause applies to:

Roller, chain, plate, or belt conveyors

Horizontal or slightly inclined transport

Any unit load (UL) such as pallets, boxes, bins, or totes

It specifically says:

“Contact with the unit load shall not cause significant hazards at the indicated speed. If higher speeds are used, safeguarding shall be required.”

What Is the “Area Type”?

The safety of speed depends on how close people are to the conveyor. EN 619 defines 3 area types:

Area Type	Description
Working Place	Where people work near or handle the load
Traffic Area	Where people pass by occasionally
Restricted Area	Where access is limited (e.g., fenced zone)

Table 1 – Maximum Speeds When Load Is Within Conveyor Width

This table applies if the unit load fits fully within the conveyor’s width.

Area	Mass >100 kg	50–100 kg	35–50 kg	1–35 kg	≤1 kg
Working	0.5 m/s	1.0 m/s	1.5 m/s	2.0 m/s	No limit
Traffic	0.6 m/s	1.0 m/s	2.0 m/s	2.5 m/s	No limit
Restricted	1.0 m/s	2.0 m/s	5.0 m/s	6.0 m/s	No limit

Example:

A 1300 kg pallet (very heavy!) moving on a floor-level chain conveyor in a manual loading zone (working place) must be limited to 0.5 m/s — that’s just 30 m/min.

Table 2 – Speeds When Load Overhangs Conveyor by up to 150 mm

This table applies when the load extends beyond the conveyor on either side, up to 150 mm. The overhang adds risk of collision or snagging.

Area	Mass >100 kg	50–100 kg	35–50 kg	1–35 kg	≤1 kg
Working	0.5 m/s	1.0 m/s	1.0 m/s	1.5 m/s	No limit
Traffic	0.6 m/s	1.0 m/s	1.5 m/s	2.0 m/s	No limit
Restricted	1.0 m/s	1.5 m/s	2.0 m/s	2.5 m/s	No limit

Example:

If your pallet sticks out by 100 mm on each side (within 150 mm), and the area is a pedestrian aisle (traffic area), then:

For a >100 kg pallet, your conveyor speed is limited to 0.6 m/s

What If the Load Overhangs by More Than 150 mm?

The standard adds a special clearance rule if the unit load extends beyond 150 mm:

If overhang exceeds 150 mm, then the clearance between the unit load and the floor must be:

≥500 mm, so it’s clearly visible and avoidable

OR

≤30 mm, so it’s impossible for a foot or leg to go under it

This reduces the risk of crush or trip hazards.

Special Notes:

If your conveyor can’t go more than 50% over the speed by design (e.g., VFD with max limit), then speed is not classified as a safety function.

For human-robot shared workspaces or collaborative conveyors, ISO/TS 15066 provides extra guidance for safe speeds and forces.

✅ Practical Application for a Real Conveyor 

Let’s say:

Your pallet weighs 1300 kg

Conveyor speed is 0.407 m/s

It operates in a working zone

Pallet overhangs by 100 mm

Result:

Based on Table 2, the max allowed is 0.5 m/s

Your design speed is safe and compliant

But if you increased speed to 0.7 m/s, you’d need safeguarding, such as:

Fences

Light curtains

Speed monitoring interlocks

Final Thoughts: Don’t Trade Safety for Speed

Speeding up a conveyor may boost throughput—but if you go over EN 619’s thresholds, you risk:

• Non-compliance

• Accidents

• Regulatory penalties

• Damage to goods or people

Design it right. Calculate it early. Prove it with data.

If your application requires going faster, make sure you apply technical safeguards or redesign the work zone layout.

Reference:

EN 619:2022 – Clause 4.2.1.2

*Tables 1 & 2 – Maximum Speeds Based on Load Mass and Area Type