Accessing the top of a road tanker is considered a high-risk activity that must be strictly controlled, carefully managed and, wherever possible, eliminated altogether.
There are several methods available for loading tankers. However, when loading loose materials into a tanker hatch, a conveyor system is often the safest and most efficient solution.
Using a belt conveyor allows the product to be loaded at ground level, effectively removing the risks associated with working at height. The conveyor then elevates the material directly to the tanker hatch, where a discharge sock or chute ensures the product is fed safely and accurately into the vessel.
This method offers several key safety and operational benefits:
- Eliminates the need for personnel to work at height
- Significantly reduces fall risk
- Speeds up the loading process
- Removes the requirement for wheeled plant operating close to the tanker
- Minimises manual handling
- Requires only one operative to open and close the hatch
In contrast, traditional methods often involve using a forklift to raise bulk bags above the tanker hatch while operatives stand on top of the tanker to guide the load. This approach introduces significant working-at-height and vehicle interaction risks.
By adopting a conveyor-based loading system, companies can substantially improve site safety, reduce operational risk, and increase overall efficiency.
Types of Conveyors
Mobile Conveyors
A mobile conveyor is usually the most flexible option for loading tankers.
Because it’s mobile, you’re not tied to one loading position. You can adjust the discharge height to suit different vehicles — raise it to clear the tanker, then lower it into the hatch for controlled loading.
It also means you can use the same conveyor for other jobs, such as loading trailers or skips. One machine, multiple uses.
Loading from Bulk Bags
If you’re emptying bulk bags into a tanker, a medium-sized hopper will normally do the job.
It allows the conveyor to take material away as quickly as the bag is emptied, meaning you can load a tanker in roughly the same time it takes to lift and discharge the bag.
Example: https://www.youtube.com/watch?v=VEVowh14KMo
Loading with a Shovel or Telehandler
If you’re using a loading shovel or telehandler, you’ll need a larger, heavy-duty hopper.
This type of hopper can:
- Handle the impact from larger machines
- Hold 1–2 full buckets of material at once
That way, you can load the hopper when it suits you and then run the conveyor to feed the tanker in a controlled way.
Example: https://www.youtube.com/watch?v=k16XicP__nM
Screw or Belt Conveyor?
Choosing between a screw and a belt conveyor depends on your material and required output. Here’s a simple guide:
Screw Conveyors:
- Great for bulk bags
- Ideal for fine or dusty materials (fully enclosed)
- Best for lower throughputs (up to around 20 TPH)
Belt Conveyors:
- Suitable for bulk bags or large machines
- Higher throughputs (100 TPH+)
- Very versatile – handles most loose materials
If you’re unsure, it’s always best to speak with your equipment supplier to make sure you get the right setup for your application.