In the mineral product manufacturing industry, a single mistake can cost more than just production time—it can cost lives. The sector’s Total Recordable Incident Rate (TRIR) is nearly double the average for all manufacturing, making it one of the highest-risk sectors in U.S. industry. Amputations, crushing injuries, and fatal accidents are all too common, with machinery incidents being a leading cause of severe injuries.

What’s driving these incidents? It’s often the same handful of hazards: unguarded machines, lapses in lockout/tagout, vehicle-pedestrian collisions, and poor material handling. The good news: most of these injuries are avoidable when proven protocols are supported by a Video AI platform that enables teams to act with foresight.

Today, safety professionals are turning to video AI to bridge the gap between policy and practice, surfacing risks in real time and empowering teams to act on detected risks. In this guide, we'll break down the top 4 avoidable injuries in mineral product manufacturing facilities—and, most importantly, how to mitigate them.

The cost of safety negligence in mineral product manufacturing

Even a single incident can lead to substantial fines and indirect costs like production delays, new training, and equipment repairs that multiply the financial impact. These costs are avoidable. Proactive safety programs, supported by real-time monitoring and data-driven analysis, can help reduce incidents long before OSHA gets involved.

The top 4 avoidable injuries in mineral product manufacturing: what every facility needs to know

1. Machinery-related amputations and crush injuries

Scenario:
An experienced operator reaches into a running press to clear a jam. In a split second, unguarded rollers catch his hand, resulting in a traumatic amputation.

Root Causes & Impact:
Machinery incidents are the leading cause of severe injuries, responsible for 34% of all incidents and a staggering 78% of amputations in this sector. Root causes include missing or bypassed guards, production pressures, and complacency from experienced staff. The impact is profound: 28% of all reported injuries are amputations, and the average cost per machinery amputation is $42,000–$120,000 not including indirect costs.

How video intelligence helps:
AI-powered cameras can monitor critical areas in real time, flagging when someone enters a designated danger zone near machinery. Video analytics can surface unsafe behaviors, such as people entering restricted areas near machinery, helping teams address unsafe behaviors. This forward-looking monitoring aids in standardizing safe practices and provides objective footage for coaching, reducing the risk of incidents before they happen.

2. Lockout/tagout (LOTO) failures

Scenario:
During a cleanup, a maintenance worker skips a step in the lockout process to save time. A coworker unknowingly restarts the equipment, causing a severe crushing injury.

Root Causes & Impact:
LOTO failures cause 12% of all severe incidents in this sector, including 60 fatalities annually. Common issues: skipped procedures under production pressure, inadequate audits, and "tapping out" (bypassing LOTO) especially among seasoned staff. These failures can result in amputations, fatalities, and six-figure penalties.

How video intelligence helps:
Video intelligence aids in standardizing LOTO procedures by providing a visual audit trail to improve compliance. Real-time alerts can flag unauthorized access to control panels or restricted areas during maintenance periods. Incident footage provides objective evidence for incident investigations, turning every event into a training opportunity to guard against future issues.

3. Vehicle-pedestrian collisions

Scenario:
A forklift operator, focused on a load, fails to see a pedestrian entering a shared aisle. The result: a serious struck-by injury.

Root Causes & Impact:
Forklifts, loaders, and trucks are a frequent source of severe injuries—5% of major incidents and a recurring cause of fatalities. Poorly marked walkways, distracted operators, and inadequate traffic separation are common causes.

How video intelligence helps:
AI video analytics can detect when vehicles enter pedestrian-only zones, helping teams identify high-risk areas and patterns of unsafe interaction. Operators and safety teams receive real-time alerts when safe zones are breached. Reviewing incidents footage enables teams to redesign traffic flow and reinforce pedestrian safety protocols.

4. Material handling and struck-by injuries

Scenario:
A worker attempts to manually move a 60-pound stone slab. The slab slips, crushing his hand and causing a severe fracture.

Root Causes & Impact:
Material handling injuries, including struck-by and caught-between accidents, account for 9% of all injuries and a high share of fractures and crush injuries. Lifting heavy materials without mechanical aids, improper stacking, and inadequate team lifting are frequent factors.

How video intelligence helps:
Cameras can monitor high-risk material handling areas. For example, teams can set up alerts for when people enter designated no-go zones, such as areas under suspended loads or in automated stacking zones. By reviewing footage of both incidents and successful operations, teams can continuously refine training and standardize safer material handling practices.

Pain points and impact of the injuries

How technology strengthens injury mitigation

1. Machinery-related amputations and crush injuries

Safety hurdle:
Machines are only as safe as their guards and their operators' habits. Bypassed guards or unsafe access points can turn routine work into disaster.

Tech Solution:
AI video platforms like Spot AI continuously monitor critical machines, surfacing real-time alerts when someone enters a designated danger zone. With unlimited video storage and easy search, teams can quickly analyze incidents to reinforce best practices before an incident occurs. This rapid insight empowers safety teams to coach safer behaviors and reduce the likelihood of incidents before they happen.

2. Lockout/tagout (LOTO) failures

Safety hurdle:
Even the best procedures fail if not followed. Under pressure, shortcuts happen, and the consequences are severe.

Tech Solution:
Video AI acts as a digital teammate, providing a visual audit trail of LOTO procedures. Supervisors can quickly review footage to confirm compliance or spot unsafe "tapping out" behavior. Automated alerts flag unauthorized access to control panels, making it easier to enforce—and prove—safe practice.

3. Vehicle-pedestrian collisions

Safety hurdle:
Forklifts and trucks share space with foot traffic, especially in busy yards and loading docks. One blind spot can mean tragedy.

Tech Solution:
Spot AI’s video analytics can identify high-risk intersections by tracking how often vehicles enter pedestrian-only zones. Real-time alerts notify teams when pedestrians enter vehicle zones, enabling timely interventions.

4. Material handling and struck-by injuries

Safety hurdle:
Manual handling is part of the job—but when corners are cut, the risk of crush and struck-by injuries climbs.

Tech Solution:
Video platforms can monitor storage and staging areas, alerting teams when people enter restricted zones, such as areas reserved for automated equipment or unstable materials. Footage of incidents and daily operations allows safety teams to refine training and layouts for safer handling.

Practical implementation of safety technology

Integrating video intelligence into mineral product manufacturing doesn’t mean starting from scratch. Capable solutions, like Spot AI, are designed to work with both new and legacy cameras—no need for a full rip-and-replace. Plug-and-play hardware bridges on-prem cameras to a secure, cloud-native dashboard, giving safety, IT, and operations teams a unified view of plant activity.

• Start with risk mapping: Identify your most injury-prone processes—machine interface points, elevated walkways, loading docks.

• Layer technology over protocols: Use video AI as a safeguard, not a replacement, for existing procedures. Help automate compliance checks, not just incident reviews.

• Involve the frontline: Train supervisors and operators to use video tools for self-audits and safety huddles.

• Prioritize privacy and compliance: Ensure video solutions align with OSHA recordkeeping and privacy regulations.

• Use data for improvement: Use incident data to drive ongoing improvement, not just compliance.

When evaluating a solution, focus on ease of integration, actionable alerts, and the ability to support your existing safety culture—not just bells and whistles. The goal: make it easy for your team to mitigate injury risks, not just document them.

Ready to improve safety in mineral product manufacturing?

By learning from incidents and addressing avoidable injuries, you can build a stronger safety culture. With the right technology and a commitment to proactive safety, mineral product manufacturing can become a model for injury mitigation. Want to see how video intelligence fits with your safety goals? Book a safety consultation with our team and take the first step toward a safer, smarter workplace.

Frequently Asked Questions

How can video intelligence improve compliance with safety protocols?

Video intelligence platforms offer real-time alerts and searchable records, making it easy to verify that procedures—like lockout/tagout or machine guarding—are being followed. This supports both proactive risk mitigation and rapid response when protocols are missed.

What obstacles do manufacturers face when implementing safety technology?

Key hurdles include integrating new solutions with existing camera systems, ensuring staff adoption, and maintaining privacy and regulatory compliance. The best platforms offer plug-and-play integration and unlimited user seats, making rollout straightforward.

How does video analytics support OSHA compliance?

Video footage offers an objective record for incident investigations, training, and audits. It also supports digital recordkeeping, which is part of proposed OSHA requirements for timely injury data submission.

How can safety teams use technology to mitigate vehicle-pedestrian collisions?

AI-powered video analytics can detect and alert when vehicles or people enter restricted zones, helping map traffic patterns to support the redesign of walkways and loading zones. These insights enable teams to take anticipatory measures to reduce collision risks.

What’s the first step to adopting video intelligence for safety?

Start with a risk assessment to identify your highest-priority hazards. Then, choose a solution that integrates easily with your existing infrastructure and supports your safety goals. Consult with vendors who understand the unique demands of mineral product manufacturing.

What is the best video analytics for workplace safety?

The best solutions work with your existing cameras and provide real-time, actionable alerts for critical events like danger zone breaches. A strong platform should also offer powerful search tools to quickly find footage of incidents or unsafe behaviors, helping teams understand root causes and identify risks before they lead to injuries.

How are top manufacturers using AI to reduce downtime and accidents?

Top manufacturers use video AI to shift from reactive documentation to forward-looking risk mitigation. They focus on addressing the most common occurrences by monitoring machine danger zones, auditing LOTO procedures, analyzing vehicle-pedestrian interactions in high-traffic areas.

About the author

Joshua Foster is an IT Systems Engineer at Spot AI, where he focuses on designing and securing scalable enterprise networks, managing cloud-integrated infrastructure, and automating system workflows to enhance operational efficiency. He is passionate about cross-functional collaboration and takes pride in delivering robust technical solutions that empower both the Spot AI team and its customers.