Do your part to protect the environment

opcleansweep.org

YOUR GUIDE TO OPERATION CLEAN SWEEP®
manual contain guidelines to help plastics industry
operations managers reduce the accidental
loss of pellets from the processing
facility into the environment.

Operation Clean Sweep®
PROGRAM MANUAL

opcleansweep.org© 2017 Plastics Industry Association (PLASTICS) • American Chemistry Council® All rights reserved.

Copyright
The materials and documents are protected by copyright by Plastics Industry Association (PLASTICS) and the American
Chemistry Council. The owners of the copyright hereby grant a nonexclusive royalty-free license to reproduce anddistribute the materials on this website and this workbook, subject to the following limitations:
1.
2.
3.

Materials from this toolkit must be reproduced in its entirety, without alterations.
Materials from this toolkit must be reproduced in a manner that shows the ACC-PLASTICS
notice of copyright.
Copies of the work may not be sold.

Acknowledgments
Plastics Industry Association (PLASTICS) and The Plastics Division of the American Chemistry Council (ACC) and wish
to thank all of the individuals, companies, government agencies and related industry associations (too numerous to name)who participated in the development and review of this manual.
Information
Questions about or suggestions to improve the OCS program or materials may be submitted to ocs@plasticsindustry.org
or (202) 974-5200.

tableOF CONTENTS

Introduction ................................................ 1
Plastic Pellets, Flakes and Powder in theEnvironment ............................................... 1
Value .......................................................... 2
Implementation ......................................... 4
Conducting a Site Audit ............................. 5
Worksite Setup .......................................... 6
Designing a Training Program .................. 8
Employee Participation ............................. 9Prevention, Containment and Cleanup
Procedures ............................................... 10
Pellet, Flake and Powder Transportation andPackaging ........................................................... 10
Spills and Packaging ......................................... 12
Other Transport Vehicle Concerns .................... 14
Marine Transport ............................................... 14
Waste Recycling and Disposal .......................... 15
Plastic Dust to Powder ....................................... 15

Pledge to Prevent Pellet, Flake and Powder
Loss .......................................................... 17
Checklist .................................................. 18

INTRODUCTION
The Operation Clean Sweep® (OCS) program and manual contain guidelines to help plastics industry operations
managers reduce the accidental loss of pellets, flakes and powder from the processing facility into the environment.
Globally, abatement of pellet, flake and powder loss has been included in the “Declaration of Solutions for Marine
Litter” to help industry’s role in addressing marine litter. We encourage companies to join other similar companies
globally by signing the Declaration and by adopting the OCS program.
Each procedure contained herein may or may not be applicable to your specific operation. Manual users are free to
implement the sections and steps that help achieve their company’s specific goals. None of the guidelines are intended as a mandate. Compliance with state and local regulations is mandatory. These guidelines may help you to achievecompliance and avoid penalties.
There are many ways to work toward zero pellet, flake and powder loss.
The OCS materials are designed to provide maximum utility for all types of plastic handling and transporting operations. The online checklists have been created to facilitate customization for your company. For example, eachchecklist may incorporate a unique company logo and specific process steps may be added or removed to reflect
those involved in a particular operation. These enhancements will make it easy to create and copy forms that have thegreatest value for your company.

PLASTIC PELLETS, FLAKES AND POWDER IN THE
ENVIRONMENT
Pellet, Flake and Powder Loss — Its Impact and Its Management
In recent years and with increasing frequency, researchers have reported that seabirds, turtles and fish are ingesting awide variety of plastic items, including pellets, flakes and powder that could affect their ability to breathe, swallow ordigest foods properly. Most of these plastics are used in consumer products (e.g., bottles, caps, containers) that havebeen carelessly discarded. Some of this litter is in the form of resin pellets, flakes and powder that enter the waste
stream and can end up in the ocean and our natural environment. When these pellets, flakes and powder are accidentally eaten by wildlife, they may not pass through their digestive tracts, which could lead to malnutrition or evenstarvation. The impacts of ingested marine debris can be significant and warrant efforts to prevent plastic materials
from entering the environment.
While consumers are responsible for the proper recycling and disposal of consumer products and packaging, theplastics industry must focus on proper containment of plastic pellets, flakes and powder. We must prevent the pellets,
flakes and powder from getting into waterways that eventually lead to the sea.
Operation Clean Sweep®: Program Manual1All employees in every aspect of the industry must be educated on how to properly handle and dispose of plasticpellets, flakes and powder with the goal of zero pellet, flake and powder loss.

The OCS Program
Plastics Industry Association (PLASTICS) began an education effort in the early 1990s to reduce pellet loss by
resin producers, transporters, bulk terminal operators and plastics processors. A number of public service materials
under the name of Operation Clean Sweep (OCS) were developed and disseminated to companies nationwide. The
message was simple: resin pellets should be contained, reclaimed and/or disposed of properly. It’s now time torefocus our industry on this problem and to expand the OCS initiative to solve it.
The American Chemistry Council (ACC) and PLASTICS have worked together on a revitalized OCS program tostrengthen ef-forts to educate and change behavior in the plastics industry with a goal of zero pellet, flake andpowder loss. ACC and PLASTICS are strongly committed to this effort and are encouraging plastics companies toparticipate in the OCS program, which includes the practices and tools outlined in this manual. In addition, ACC and
PLASTICS are encouraging companies to sign onto the Declaration for Solutions to Marine Litter, of which the OCS
program is a key element. Only by working globally can industry help to affect the introduction of pellets, flakes andpowder into the environment.

How You Can Help
Each segment of the industry – whether resin producers, transporters, bulk
terminal operators or plastics processors – has a role to play in eliminating
resin pellet, flake and powder loss. It’s the little things that count – a few
pellets, flakes and powder here, a handful there. They all add up when you
consider the thousands of facilities in the industry and the frequency withwhich resin pellets, flakes and powder are loaded and unloaded.
Commitment by everyone in every company, from top management toshop floor employees, is essential to eliminating pellet, fl ake and powder
loss.
Pellet, flake and powder containment is good for the environment. It’s goodfor business – pellet, flake and powder loss represents a source of revenue
loss. And, in many jurisdictions, there are separate legal or permit requirements addressing pellet, flake and powder loss.
With your help and cooperation, we can make great strides to help ourin-dustry protect the environment. ACC and PLASTICS look forward toworking with you on Operation Clean Sweep to accomplish this important
goal.

VALUE
If you could take a simple step to help strengthen your company’s:
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sustainability initiatives;contribution to preserving water quality and wildlife;
compliance with federal and state regulations and avoidance of fines;
safety/housekeeping program;
employees’ well-being;
Operation Clean Sweep®: Program Manual•••

operational efficiency;
financial bottom line; andreputation in the community…

...would you take it?
That step is Operation Clean Sweep (OCS), a product stewardship program of the American ChemistryCouncil’s Plastics Division and Plastics Industry Association (PLASTICS).

The campaign’s goal is: to help every plastic resin handling operation implement
good housekeeping and pellet, flake and powder containment practices to work
towards achieving zero pellet, flake and powder loss. OCS is being conductedin thousands of plants around the world, all adding to the effort to protect theenvironment.
Pellet, flake and powder loss has many negative impacts on individual companies, on the plastics industry as a wholeand on the environment.
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Slips and falls are a major cause of plastics industry accidents.

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Accidents mean lost work time, higher worker compensation costs and lower employee morale.

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Violations of storm water regulations in states like California can result in civil penalties of up to $3,000 per incident (e.g., Cal. Code. Regs. title 23 § 13385). Any person discharging unauthorized waste in violation of CWC§ 13264, could be found guilty of a misdemeanor and may be fined up to $1,000 a day.

•Spilled pellets, flakes and powder can eventually end up in our waterways and the ocean. Whether they’rehandled in an Iowa plant or a seaside facility, pellets, flakes and powder can be transported to storm drains thatlead to rivers and then to the ocean — resulting in litter and posing a threat to marine life such as sea birds,
turtles, and fish.

When the industry handles pellets, flakes and powder as responsibly as possible:•

Pellets, flakes and powder are kept out of the natural environment, including waterways and oceans;•

Companies enhance their reputations as good stewards of the environment — an increasingly important factor
for attracting the investment community and high-quality employees; and•More material stays a valuable product rather than becoming waste, improving efficiency.

OCS’ ultimate goal is to help keep plastic pellets, flakes and powder out of the environment, but these efforts can also
help improve relations with stakeholder groups and community organizations that expect the industry to minimize its
environmental footprint.
The industry needs every processor’s help to get positive results.
Please contact us with any input or questions: PLASTICS: (202) 974-5200 or email ocs@plasticsindustry.org.

Operation Clean Sweep®: Program Manual3

IMPLEMENTATION
1. Commit to making zero pellet, flake and powder loss a priority.
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Sign the “Pledge to Prevent Resin Pellet, Flake and Powder Loss.”

2. Assess your company’s situation and needs.
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Comply with all environmental laws and regulations that address pellet, flake and powder containment.
Conduct a site audit.
Determine if you have appropriate facilities and equipment.
Determine if employees have and are following appropriate procedures.
Identify problem areas and develop new procedures to address them.
Communicate your experiences to peers in the industry.

3. Make necessary upgrades in facilities and equipment as appropriate.
4. Raise employee awareness and create accountability.
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Establish written procedures (The procedures and checklists in this manual may be modified to suit yourneeds. They are available in the checklists section.
Make certain the procedures are readily available to employees.
Conduct regular employee training and awareness campaigns on OCS.
Assign employees the responsibility to monitor and manage pellet, flake and powder containment.
Encourage each worker to sign the employee commitment pledge.
Solicit employee feedback on your program.
Use workplace reminders such as stickers, posters, etc.

5. Follow up and enforce procedures - when management cares, employees will too.
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Conduct routine inspections of the facility grounds - production areas and parking lots, drainage areas,
driveways, etc.
Continuously look for ways to improve the program. Share best practices through the OCS Website

Operation Clean Sweep®: Program Manual

CONDUCT A SITE AUDITOne of the most effective ways to improve your facility’s containment of pellets, flakes and powder is to identify theareas where spills and losses occur most frequently and fix them.
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Use the site audit checklist to audit every transfer point at your site.
Identify the major spill areas.
Determine the cause of spills in each area.
Research/brainstorm ways to solve each problem.
Implement the simplest effective solution.
Follow up to measure success.
Repeat as necessary.

Most companies may not perform all of the operations on the site audit checklist. Customize the checklist to suit yourfacility. Add any missing operations.

Operation Clean Sweep®: Program Manual5

WORKSITE SETUP
Ensure your worksite is properly set up to prevent loss and assist cleanup.
EPA Regulations

FACILITIES – take the following steps wherever possible and practical:•

EPA regulates the discharge of storm
water effluents via the National Pallutant Discharge Elimination Systems(NPDES) permitting program (40C.F.R. §122)

To pave or not to pave — that is the question A paved area facilitates cleanup, but allows pellets, flakes and powder to be carried into storm drains and the environment by wind andwater.
 Unpaved areas are more difficult to clean, but pellets, flakes and powder tend to stay where they fall and canbe easily recovered.
Choose the solution that is best for your facility.
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Pave loading/unloading areas where unavoidable spills occur to facilitate cleanup Include a slope or a berm to contain pellets, flakes and powder within paved areas.
 Equip areas with vacuums or brooms and dust pans.
 Cordless vacuums may be best suited for outdoor cleanup.

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For cleanup in gravel yards, consider fitting vacuums with screen or
Prepare for Flooding
mesh on intake hoses to collect pellets, flakes and powder without disMake sure the containment system
turbing gravel.
can handle heavy rains and flooding.
Provide catch trays for use at all car/truck unloading valves.
The system should be capable of hanUse bulk-handling equipment that is designed to minimize pellet, flake dling 100-year flood conditions.
and powder leakage.
Install central vacuum systems where practical.
Install connecting hoses equipped with valves that will close automatically when the connection is broken.
Properly empty and seal bulk containers (rail or truck) prior to shipment. Loss of residual pellets, flakes andpowder from unsealed “empty” bulk cars and trucks is a significant problem.
Place pellet, flake and powder disposal cans at rail yards for loading and unloading.
Assure proper handling when storing and removing waste pellets, flakes and powder. All vendors should
follow “no loss to the environment” procedures.
Seal expansion joints in concrete floors with a flexible material to avoid pellet, flake and powder accumulation in hard to clean spaces.
Conduct routine inspections and maintenance of equipment used to capture and contain pellets, flakes andpowder.

Containment Systems••

Anticipate Rain

Storm drain screens are the last line of defense against accidental pellet, flake and powder release. They should be every facility’s # 1 priority
for installation.
Install zero loss containment systems (such as storm drain screens)wherever necessary to prevent pellets, flakes and powder from escaping plant boundaries. There are two possible containment systems that
could be installed:

Design systems to handle 100-year
flood conditions.
Use a collector grate and filteredstorm drain system with a screen consistent with the range of pellet, flakeand powder size handled.

 Area-specific containment systems in each pellet, flake and powder handling area. Area-specific con6

Operation Clean Sweep®: Program Manualtainment systems would be the primary pellet, flake and powder containment systems and the facility-wide system would serve as a backup.
 Facility-wide containment systems, which are effective in controlling pellet, flake and powder releases
from facilities covering a large area and handling large volumes of pellets, flakes and powder.
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Place screening in all storm drains. The mesh of the screening should be smaller than the smallest pellet,
flake and powder handled at the facility. Clean the storm drain screens weekly to prevent drain clogging andoverflow. Pay particular attention to cleaning screens after every rain. Two-stage screens minimize clogging
problems.
Install baffles, skirts and booms in containment ditches or ponds. Use surface skimmers or vacuum systems
to remove accumulated pellets, flakes and powder.
To prevent storm drain contamination, employ dry cleanup methods whenever possible. Dry cleanup procedures also prevent pellets, flakes and powder from being further contaminated by compounds in the storm
water.

Employee Equipment - ensure that employees have ready access to:
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Brooms, dustpans, rakes, etc.
Heavy-duty shop vacuums for inside use
Portable shop vacuums for outside use
Catch trays or tarps
Wide-mouth sample collection jars or poly-bags
Tape for repairing bag or box damage
Scrap pellet containers (drums, bulk boxes, etc.)
Procedures you expect workers to undertake and checklists to assist in follow-through. (Checklists are available to customize).
Forklift cleanup kit (see page 13)
Assure that employees have ready access to the proper cleanup equipment at all locations where spills
might occur
Slips and Falls
Slips and falls are the number one cause of plastics industry accidents.

A Clean Work Area
A clean work area reduces slips and falls and improves employee morale.

Operation Clean Sweep®: Program Manual

7

DESIGNING A TRAINING PROGRAM
Designing a training program involves a sequence of steps that can be grouped into five phases: conducting a needs
assessment, defining training objectives, detailing program specifics, implementing the training and evaluating its
effectiveness.
1.

Needs assessment - conduct a site audit (pages 8 and 29-31) and determine if employees have and are following appropriate procedures. Make needed site improvements and write/modify procedures prior to launchinga training program.

2. Instructional objectives - identify what training is needed to ensure procedures are being followed.
3. Details - determine how, who, where and when you will train. Consider the following areas: explaining theenvironmental impact of pellet loss, defining the role each individual plays in affecting change and ensuringknowledge of appropriate procedures.
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Use OCS to design and develop the training program and program content.
Select the techniques used to facilitate learning (crew meetings, handouts, video, website, etc.).
Select the appropriate setting for your meetings.
Prepare materials.
Identify and train the instructors
Create department goals.

4. Implementation - Schedule classes, facilities, participants and instructors, deliver materials, conduct training.
5. Evaluation - Determine participant reaction to the training, how much they learned and to what degree the department goals were met. Re-evaluate all procedures to assess the effectiveness of the OCS program annually.

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Operation Clean Sweep®: Program ManualEMPLOYEE PARTICIPATION AND ACCOUNTABILITY
Ensure employees are aware of and accountable for pellet, flake and powder loss
prevention, containment, cleanup and disposal. Establish written procedures.
(The procedures and checklists in this manual may be modified to suit yourneeds. They are available in the Checklists section of this website).
Make certain the procedures are easily available.

Spills Will Happen
Ensure that employees:• Take ownership by taking thepledge.
• Immediately clean up the spill.
• Recycle or dispose of loose pellets, flakes and powder properly.

Conduct regular employee training and awareness campaigns on the Operation
Clean Sweep program.
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Explain the impact of pellet, flake and powder loss on the environment and the company.

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Make spill prevention, cleanup and containment a company philosophy and priority.

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Promote that philosophy daily.

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Assign specific employees the responsibility to monitor and manage pellet, flake and powder containment. If it
gets assigned as a regular part of employee jobs, it gets done.

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Consider hiring a full-time housekeeping/warehouse sweeper, if appropriate. Having one person assigned thisjob improves the efficiency of other workers.

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Stress the importance of immediate cleanup of any spills by the person
associated with the spill.

Acknowledge Hard Work
Simple steps, like bringing in a special
lunch, to acknowledge employee’s
hard work to prevent loss can go along way in keeping your company’scommitment front and center•

Review current procedures and identify whether there has been a historyof problems in a certain area.

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Reaffirm existing, or develop new, procedures.

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Use workplace reminders such as stickers, posters, etc.

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Encourage teamwork and employee feedback.

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Conduct regular inspections of the entire facility to assure compliance with OCS principles.

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Reward and/or recognize milestones and significant achievements of the crew or crews that achieve designated goals of the pellet, flake and powder loss prevention program.

Operation Clean Sweep®: Program Manual9PREVENTION, CONTAINMENT AND CLEANUPPROCEDURES
There are many steps involved in the movement of plastic pellets, flakes and powder from the resin production facility,
through the distribution network, to the processor. Spills and pellet, flake and powder loss to the environment can occur at any step. The procedures in this section provide best practices for each handling step. Making employees awareof and holding them accountable for these prevention, containment, cleanup and disposal procedures, is the way tozero pellet, flake and powder loss.

Rail Car/Truck
Cleaning

Car/Truck
ReturnResin
Production

Hopper Car
Loading

Customer
SiloTransfer/Storage

Resin
Production

Process
Feeding

Truck
Transfer/Loading
Customer
Warehouse

Box
Filling

Bag
Filling

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Operation Clean Sweep®: Program ManualProcedures: Pellet, Flake and Powder Transport and Packaging
Hopper car and hopper truck cleaning, loading, storage and unloading present special resin handling challenges.
Cleaning Empty Hopper Cars and Trucks••••

Use air lance to make total pellet, flake and powder removal easier.
Ensure hopper car and truck cleaning areas have wastewater collection
and pellet, flake and powder filtration systems installed.
Recover all pellets, flakes and powder from wash water.
Recycle, resell or dispose of collected pellets, flakes and powder properly.

Cleaning Cars & Trucks
Ensuring proper handling of residualmaterials.

Top Loading Hopper Cars and Trucks•••

Operate the conveying system properly to avoid clogging and necessitating the opening of lines.
If a line must be opened to clear blockage, anticipate the potential for pellet, flake and powder loss and always
place a catch pan or tarp under the connection.
Remove any spilled pellets, flakes and powder from the top of the car/truck before leaving the containment area
- residual pellets, flakes and powder will fall to the ground as cars are moved outside the plant.

Sealing Loading Cars/Trucks•••

Close all outlet caps properly before cars/trucks are moved (and request customers to do the same when returning empties).
Apply seals on all outlet caps (1/8” stranded steel cable or its equivalent).
Design or modify loading systems so that transfer lines can be completely emptied, with any residual resin
being discharged into a container after loading is completed.

Storing at Intermediate Sites•••

Consider exposure to vandalism when selecting sites.
Establish security procedures as necessary (e.g. fencing and lighting).
Advise companies to report any incidents (e.g. shippers, railroads, trucking companies and processors).

Unloading Hopper Cars and Trucks
Valve Opening
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Be Vigilant
Pellet, flake and powder loss can occur at any stage of operations. Be
vigilant to ensure that pellets, flakes
and powder don’t escape into the environment.

Contain any possible spill during hook-up by placing a catch pan under theunloading valve before opening.
Purge unloading tubes within containment area.
Keep area swept up or vacuumed.
Consider installing connecting hoses equipped with valves that will close
automatically when the connection is broken. Clogged hoses, material bridging in outlets, etc., can require unloading lines to be opened, which presents the risk of spillage.
Anticipate the potential for pellet, flake and powder loss before opening the line.
Place pellet, flake and powder disposal cans at rail yards for loading and unloading.
Have a catch pan or tarp ready to catch pellets, flakes and powder.
Immediately clean up and properly dispose of any spilled pellets.
Surges in unloading lines can cause pellets, flakes and powder to be vented into the environment. To prevent
this, install a bag house, filter bag assembly or other control device at the unloading system vent.

Operation Clean Sweep®: Program Manual11Completing Unloading••••

The “Usual Suspects”
Open valves, outlet caps and top
hatches are frequent causes of material spills. Make sure to close off allpellet “Escape routes” once the car isunloaded.

Ensure that the car/truck is thoroughly unloaded.
Cycle the outlet valve while air is flowing.
Visually confirm that each compartment is empty.
Purge the line before disconnecting.

Sealing Valves••

Close all valves.
Secure outlet caps and top hatches.

Sampling•••••

Conduct sampling only in areas protected by containment equipment.
Review procedures for taking samples to eliminate any possible spillage.
Use wide-mouth containers or poly-bags for samples.
Use a funnel collection system to effectively channel pellets, flakes and powder into containers.
Sampling from unloading tubes:
 Place a catch pan or heavy duty tarp under outlet before opening to catch any spills. (Several commercial
devices have been developed specifically for preventing spills during sampling.)•

Sampling from top hatches: Exercise extra caution to avoid spillage, which can also pose a slipping hazard.
 Close hatches and apply cable seals to prevent access by vandals.

Procedures: Spills and Packaging
Spills••Exercise caution to avoid spillage.
Clean up any spills immediately.

Packaging
Using the proper packaging, filling and material-handling procedures can go a long way in minimizing pellet, flakeand powder loss.
Selecting Packaging Materials•••

Use packaging designed to minimize the possibility of breakage and pellet, flake and powder leakage. Use puncture-resistant shipping containers where possible.
Use reinforced bags, such as woven polypropylene bags, and line larger containers with puncture-resistantmaterial.
Minimize the use of valved bags, or seal valved bags immediately after filling.
Collecting Spilled Pellets, Flakes and Powder
Collecting spilled pellets, flakes and powder reduces contamination, permitting normal usage rather than requiring disposal.

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Operation Clean Sweep®: Program ManualBags: Filling and Handling
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CautionShipping bags often use a mechanicalInspect all pallets for protruding nails or broken boards.
closure that does not provide a posiUse bags that are not easily punctured.
tive seal against leakage once the bag
Use a heavier weight container/bag if breakage is a recurring problem.
is filled.
Move and stack bags immediately after filling to avoid seepage.
Tape leaks or replace leaking bags.
Regularly clean up pellets, flakes and powder spilled during the filling process. Where possible, select filling
equipment designed to prevent pellet, flake and powder loss.
Implement warehouse and handling procedures that minimize the chance of pellet, flake and powder spillage.
Dispose of collected pellets, flakes and powder properly.

Bags: Emptying and Disposal
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Thoroughly empty bags.
Collect, handle, store and transport the empty bags to avoid/contain the escape of pellets, flakes and powder.
Recycle plastic resin bags, shrink-wrap and stretch-wrap, whenever possible. Visit www.plasticfilmrecycling.org
for more information.
Dispose of packaging by incineration or in a well-managed landfill.
Stress the need for “no loss to the environment” procedures.

Bulk Boxes••••

Use bulk boxes that are not easily punctured.
Tape leaks or replace leaking boxes.
Regularly clean up pellets, flakes and powder spilled during the filling process.
Dispose of collected pellets, flakes and powder properly.

CautionSome loss also occurs during the filling process.

Improve Palletizing Methods
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Move and stack bags immediately after filling to avoid seepage fromvalves.
Stack bags on pallet in tight, interlocking patterns.
Shrink or stretch-wrap pallet to stabilize stacks and help contain lost pellets, flakes and powder.
Use corrugated cardboard caps on the top and bottom of pallets to minimize puncturing or tearing bags and to contain loose pellets, flakes andpowder.
Block and brace outbound loads to avoid broken bags in transit.

Select Proper Bags and Pellets,
Flakes and Powder
Bags typically are stacked 40 to 50
per pallet, and pallets are usually sorted at least two high. Both individual
and palletized bags are subject to therigors of warehouse movement andstorage. Proper bag and pallet selection can help reduce damage.

Handling Materials
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Forklift operators must be trained and skilled in damage prevention as wellas proper cleanup.
Institute handling procedures that minimize puncture of bags and boxes
with forklift tines.
Repair or replace punctured packages and cleanup any spills immediately
to prevent loss of pellets, flakes and powder. Sealing a leak when it occurs
is much easier than sweeping 100 yards of warehouse.
Consider outfitting all forklifts with a Cleanup Kit.
Place catch trays between the dock and trailer at shipping and receiving
bays.

Operation Clean Sweep®: Program Manual

Forklift Cleanup Kit
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Broom
Long-Handled Dust Pan
Repair Tape
Bucket for Collection/Disposal

Select these items to fit together inthe bucket to the forklift using elastic
cords. Situate the kit so as not tointerfere with the safe operation of theforklift.

13•Inspect pellet, flake and powder packaging before offloading, particularly pellets, flakes and powder bagged inunreinforced paper or corrugated bulk boxes. This will prevent pellet, flake and powder release through the gap
between the vehicle and the loading dock.
Storage•

Consider covering all packaging resin stored outside (gaylords, supersacks, etc.) to prevent photo degradationof the containers.

Procedures: Other Transport Vehicle Concerns
Container Trucks•

Shipping
 Sweep or vacuum any loose pellets, flakes and powder in the truck/container.
 Carefully inspect empty trailers for damaged interior walls or defective floors that can tear bags. Consider refusing to use such containers or cover problem areas with corrugated liner board.
 Block and brace outbound loads to avoid broken bags in transit.

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Receiving Inspect truck and rail shipments containing palletized bags of pellets, flakes and powder and document
the condition of bags and pallets received. If the shipment is significantly damaged, notify the transporterand manufacturer. Consider refusing to accept delivery.

Hopper Cars and Trucks – Repairs••

Work in a paved area to facilitate containment and cleanup.
Properly contain, handle or recycle small quantities of residual pellets, flakes and powder. If larger quantities
are involved, contact the shipper.

Transport Accidents•

Contact the shipper for assistance/advice if a derailment or highway accident results in a spill of resin pellets,
flakes and powder.

Procedures: Marine Transport
Marine transport of pellets, flakes and powder requires special attention due to the high potential for release into theenvironment. Because of the close proximity to water, loose pellets, flakes and powder in and around waterfront warehouses, docks, ocean-going containers and on ships themselves must receive extra attention.
Anyone handling pellets, flakes and powder directly or managing their shipment must be well-informed about theimportance of spill prevention, the need for prompt cleanup and proper disposal practices.
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Do NOT sweep pellets, flakes and powder into the water.

Operation Clean Sweep®: Program Manual

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Properly contain and handle any pellets, flakes and powder from previous shipments when cleaning ship holds
or ocean containers.
Keep ocean containers in good repair – eliminate protrusions that could tear bags and boxes.
Avoid stowing resin containers on deck. Place resin containers in ship holds.
Do NOT jettison containers of resin.

Procedures: Waste Recycling and Disposal
Ensure pellets, flakes and powder are properly disposed of to avoid contaminating the environment.
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Store waste pellets, flakes and powder in properly labeled containers.

Preferred Disposal Methods• Recycle• Resale• Approved Incineration (whereavailable)• Controlled Landfill• Fuel-Blending Program Do not permit loose pellets, flakes and powder to accumulate on the
ground or floors.
 Install a minimum of one pellet-specific waste container in each pellet-, flake- and powder-handling area.
 Routinely check that there is adequate waste storage capacity.
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Use separate containers for recyclable and non-recyclable pellets, flakes and powder.
Use only covered containers or vehicles without leaks.
Inspect and confirm proper handling and storage procedures if an outside vendor is used for waste removal.
 Stress the need for “no loss to the environment” procedures.

•

Preferred disposal methods are:Final Step
Careful disposal is the final step toensuring that pellets, flakes and pow Recycle or resell waste pellets, flakes and powder.
 Approved incineration of waste pellets, flakes and powder in prop- der do not affect the environment.
erly licensed and operated incinerators.
 Deposit in a controlled landfill only after confining pellets, flakes and powder in such a manner that prevents their loss due to rain, wind, flooding, etc.
 Consider using waste pellets, flakes and powder in a fuel-blending program.

•

Include pellet, flake and powder retention capabilities and practices in criteria for selecting waste disposal
companies.

Procedures: Dust and Powder
Methods to Help Minimize Generation and Release of Plastic Dust and PowderThis specifically focuses on methods to help minimize generation and release of plastic dust and powder. There
are several approaches that can be taken. You may wish to consider whether other ways are more appropriate foryour operations. Consult with the manufacturer of the resin you are handling for specific handling, containment anddisposal information.
For purposes of this discussion:
Plastic Dust is particulate matter that may be formed when plastics are handled, conveyed and/or processed. Oneof the most common means of generation is via abrasion during the air conveying of plastic pellets and flakes. In
addition to conveying, plastic dust may be generated when plastic raw materials or finished products are:Operation Clean Sweep®: Program Manual

15

•
•
•
•
•
•

Granulated;
Pelletized;
Cut;
Machined;
Filed; orTransported

Plastic Powder is a form of plastic raw material used in operations where a fine particle size is critical for processing. Plastic powder can escape plastic handling or processing equipment. If that occurs; handling, containment andrecovery considerations are similar to plastic dust. Typically powders may escape through:••••leaks in storage silos, tanks and containers;
leaks in pneumatic or mechanical conveyors;
leaks in blenders or other processing equipment; orduring loading/unloading operations or transfer operations.

Methods to Consider for Minimizing the Generation of Plastic Dust
The best way to control dust is to minimize its creation in the first place. There are several approaches that can betaken to help minimize the generation of plastic dust. For example:
•
•
•
•
•
•

When pelletizing or flaking, keep cutting equipment in good condition with sharp blades;
Design conveying systems to treat the plastic gently and take other steps to help avoid collisions and impacts
with hard surfaces and other pellets, flakes and powder, thereby avoiding plastic fracture. Methods to consider,
can include, use of long sweep elbows and avoid having the plastic pass through a blower;
Use appropriately sized granulators;
When machining plastics, use an appropriate machine set up for the material and provide appropriate waste
collection equipment;
Store plastics and additives in appropriate containers maintained in good condition; andPromote awareness to employees of methods of handling and processing of the plastic to help minimize dust
creation.

Methods to Consider for Minimizing the Release of Plastic Dust and Powder
There are several approaches that can be taken to help minimize the release of plastic dust and powder. For example:
•
•
•
•
•
•
•
•

Keep storage silos, tanks and containers in good condition, to help avoid holes, cracks or leaks;
Maintain loading/unloading and transfer equipment with good seals to help avoid leaks;
Conveying equipment should be appropriate for the task and maintained in good condition;
Place collection trays under discharge/loading valves and connection points when making or breaking connections;Use processing equipment (and the equipment that feeds it) that helps minimize the release of dust/powder;
Clean up all spills promptly; wind and traffic can quickly disperse dusts and powders;
Encourage employees and/or contractors to look for dust/powder leaks and to correct any that occur; andPromote employee awareness of training and reminders regarding the need to prevent dust/powder from escaping into the environment.

Methods to Consider for the Capture and Containment of Plastic Dust
Plastic dust creation can be minimized but not eliminated entirely. There are several approaches that can be taken
to help in the capture and containment of plastic dust.1 For example:
Dust from plastics may combine with dust from other materials within the plant site. Review MSDS for information on the proper capture, containment anddisposal equipment and procedures.

1

16

Operation Clean Sweep®: Program Manual

•
•
•
•
•
•
•
•
•

Use properly designed and sized dust collection equipment in all operations that generate or liberate plastic
dust;
Maintain the dust collection equipment according to manufacturers’ recommendations;
Use the recommended filters for the type and amount of dust generated;
Clean or replace filters or other collection equipment as needed;
Promote awareness of procedures for clean-up of plastic dust spills, or plastic dust that has settled on surfaces
in and around the plant;
Promote maintenance/housekeeping procedures that minimize dust accumulation around the facility;
Store captured plastic dust in containers that are designed to help minimize leaks;
Promote employee awareness in procedures for handling plastic dust, including industrial hygiene considerations; andComply with applicable federal, state and local regulations for containment systems.

Disposal
Proper disposal of plastic dust and powder can be critical to help minimize the amount released to the environment.
Choosing a disposal method involves considering the materials that constitute the dust /powder and the disposal
requirements of those materials.
••

Review the MSDS for each type of plastic used in the process.
Dispose of dust or powder using a method that complies with all federal, state and local regulations and guidelines and/or applicable codes and standards.

Disclaimer: Methods to Help Minimize the Generation and Release of Plastic Dust and Powder is a part of The Operation Clean Sweep® (OCS) program, a joint
program of the American Plastics Council and the Society for the Plastics Industry, Inc. (collectively, “OCS Sponsors”). The OCS program and manual contains guidelines to help plastics industry operations managers reduce the loss of pellets, flakes and powder to the environment. Each procedure contained
herein may or may not be applicable to your specific operation. Manual users are free to implement the sections and steps that help achieve your company’s
specific goals. None of the guidelines are intended as a mandate. Compliance with state and local regulations are mandatory. These guidelines may help
you to achieve compliance and avoid penalties. OCS Sponsors do not make any warranty or representation either express or implied, with respect to theaccuracy or completeness of the information contained in this document nor do OCS Sponsors assume any liability of any kind resulting from the use or
reliance upon anything contained in this document. Compliance with applicable laws and regulations remains the full responsibility of the parties to which
the law or regulation applies.

PLEDGE TO PREVENT PELLET, FLAKE AND POWDER LOSS
Take the Pledge for Your Company
To demonstrate your commitment to a clean environment, please complete the “Pledge to Prevent Resin
Pellet , Flake and Powder Loss” or complete and fax a copy to PLASTICS at (202) 318-7507 or email to
ocs@plasticsindustry.org.
The pledge must be signed by an officer of the company. In return, your company will receive a certificate
suitable for display affirming your commitment to being an Operation Clean Sweep Partner.
Signing this pledge will qualify your company’s name to be added (unless otherwise specified) to the list of
OCS Program Partners on the Operation Clean Sweep website. Listed partner company names may be used inpublicity for the program.
Have Your Employees Take the Pledge•••

Individual personal commitment of every employee is the key to success.
Encourage every employee to be fully engaged and committed to following the OCS principles every day.
Having each employee sign a personal pledge found in the checklist section is an effective way to gain thatcommitment.

Any dust, no matter what the material, can be explosive if in the proper concentration in air. When handling dusts, take precautions not to aerate it and to keep
ignition sources away.

Operation Clean Sweep®: Program Manual

17

CHECKLISTWe have provided a number of checklists to assist you in implementing OCS. The checklists are divided into two categories: Management and Employee. The checklists have been created so they are customizable for your company.
For example, you can insert your company logo and specific process steps may be added or removed to reflect those
involved in a particular operation. These enhancements will make it easy to create and copy forms that have the greatest value for your company. For online checklists, visit: www.opcleansweep.org/Manual/Checklist.html.
Management Checklists••••

Site Audit
Implementation & Training
Facility Equipment
Employee Equipment

Employee Checklists
•
•
•
•
•

18

Processor Operations
Warehouse
Car Cleaning/Loading
Railroad
Transloader

Operation Clean Sweep®: Program ManualSiteManagement
Checklist
SITEAudit
AUDIT
MANAGEMENTCHECKLIST

opcleansweep.org
Company:
Department:
Bulk Hopper Car/Truck Unloading Area
Spill Problem:

Yes

No

Cause of Spill:
Solution:
Implementation Date:
Receiving Dock - Bags And Boxes
Spill Problem:

Yes

No

Yes

No

Cause of Spill:
Solution:
Implementation Date:
Silo Area
Spill Problem:
Cause of Spill:
Solution:
Implementation Date:
Transfer Equipment - Blower
Spill Problem:
Cause of Spill:
Solution:
Implementation Date:

Audited By:
Audit Date:

Yes

No

Transfer Equipment - Bag House
Spill Problem:

Yes

No

Cause of Spill:
Solution:
Implementation Date:
Transfer Equipment - Line Connectors
Spill Problem:

Yes

No

Yes

No

Yes

No

Cause of Spill:
Solution:
Implementation Date:
Box/Bag Handling
Spill Problem:
Cause of Spill:
Solution:
Implementation Date:
Blending Equipment
Spill Problem:
Cause of Spill:
Solution:
Implementation Date:
Processing Line - Extrusion Feed Hoppers
Spill Problem:

Yes

No

Yes

No

Cause of Spill:
Solution:
Implementation Date:

Audited By:
Audit Date:
Sampling Areas
Spill Problem:
Cause of Spill:
Solution:
Implementation Date:
Operation Clean Sweep | Site Audit Management Checklist | Page 2

Packaging Areas - Bulk Box
Spill Problem:

Yes

No

Yes

No

Yes

No

Yes

No

Cause of Spill:
Solution:
Implementation Date:
Packaging Areas - Bag
Spill Problem:
Cause of Spill:
Solution:
Implementation Date:
Warehouse/Storage
Spill Problem:
Cause of Spill:
Solution:
Implementation Date:
Shipping Dock
Spill Problem:
Cause of Spill:
Solution:
Implementation Date:

Audited By:
Audit Date:

Manager:
Signature:

Operation Clean Sweep | Site Audit Management Checklist | Page 3

IMPLEMENTATION& TRAINING
Site
Audit Management
Checklist CHECKLIST

opcleansweep.org
Company:
Department:

Procedures
Signed the “Pledge”
Conduct site audit
Review or create written procedures
Assign responsibility for each crew/individual
Put management inspection program in place
Plan follow up and review

Training
Crew training meetings conducted
Shift #1
Shift #2
Shift #3
Shift #4

Manager:
Signature/Date:FACILITY
EQUIPMENT Checklist
CHECKLIST
Site
Audit Management

opcleansweep.org
Company:
Department:

Storm Drain Screens
Number of drains:
Number of drains with screens:
Target date to complete screen installation:
Drain screen inspection/cleaning frequency:
Screen repairs required:

Unloading Areas
Paved
UnpavedTarps/catch pans available in area
Disposal receptacles in area

Transfer Systems
Bag House/filters OK
Pipe, hoses and connections leak free
Disconnects with auto closing valves

Sweepings Disposal
Contractor agrees to zero loss disposal procedures
Proper interim storage containers available

Inspected By:
Inspection Date:EMPLOYEEEQUIPMENTCHECKLIST
Site
Audit Management
Checklist

opcleansweep.org
Company:
Department:

Available For Use
BroomsDust pans
Repair tape
Vacuum system
CentralPortable
Catch pans
Sample containers
Scrap pellet, flake and powder container
Elastic cord
Buckets for forklift cleanup
Inspected By:
Inspection Date:

PROCESSOROPERATIONSCHECKLIST
Site
Audit Management
Checklist

opcleansweep.org
Company:
Department:
Operation:
Crew/Shift:
Inspector:
Date:Condition at START of Shift
Excellent

SilosTransfer Lines
Bag/Box Feeding
Dryer
Extruder Hoppers
Problem Areas
Yes
No
Spill Recovered: If not, why:
Sweeping Properly: Yes
No
Disposed of: If not, why:
Samples Taken: Number:

Inspected By:
Inspection Date:

Good

Poor

Condition at END of Shift
Excellent

Good

Poor

WAREHOUSE CHECKLIST

opcleansweep.org
Company:
Department:
Operation:
Crew/Shift:
Inspector:
Date:

Receiving Area:
Loading dock catch pans in place for receipt of container shipments
Rail truck unloading valve catch pans in place before openings
Samples collected in approved containers
Container trucks cleaned after unloading
Hopper car/truck valve covers in place before moving
Full walk around conductedTransfer lines flushed and clean
Dock area swept clean
Car/Truck unloading area clean
Raw Material Storage area clean
Aisles in clean condition
No leaking boxes
No leaking bags
Waste collection containers emptied
Boxes cleaned and flattened
Bags fully emptied prior to disposal
Broken pallets repaired or replaced
Inspected By:
Inspection Date:

CAR CLEANING/LOADING CHECKLIST

opcleansweep.org
Company:
Department:
Operation:
Crew/Shift:
Inspector:
Date:

Receiving Area:
Containment for wash area operational
Compartments empty and clean
Air lance operational
Unloading outlet tubes totally clean
Pellet, flake and powder recovery from wash water 100%

Car Loading:
No line blockages or clogging
Catch pans in place for connections
Transfer lines flushed after each car loading completed
All outlets secure and sealed after filling (Seals are all 1/8 inch braided steel or stronger)
Top
BottomTop of car clear before release
Inspected By:
Inspection Date:

RAILROAD CHECKLIST

opcleansweep.org
Company:
Department:
Operation:
Crew/Shift:
Inspector:
Date:

Storage in Transit Areas:
SecureFencedAdequate lighting
Regular Inspections
Car valve covers and seals in place or shipper notified

Inspected By:
Inspection Date:

TRANSLOADER CHECKLIST

opcleansweep.org
Company:
Department:
Operation:
Crew/Shift:
Inspector:
Date:

Receiving Area:
Wash system containment operational
Compartments empty and clean
#1
#2
#3
#4
Unloading outlet tubes totally clean

Transfer (Transfer area: Gravel

Asphalt)

Car seals in place before start of transfer
Catch pans in place prior to valve opening
Transfer lines flushed and clean after transfer
All outlets secure and sealed at completion and prior to moving
Car
Top
BottomTruck
Top
BottomSpills cleaned and disposed of properly
Samples taken without material loss
Unloading problems experienced
Inspected By:
Inspection Date:Pledge to Prevent Resin Pellet, Flake and Powder Loss

Employee Pledge to Prevent Resin Pellet, Flake and Powder Loss
I recognize our company’s commitment to Operation Clean Sweep and thegoal of preventing pellet, flake and powder loss into the environment. I will
do my daily job in a manner that strives to:••••Prevent Pellet, Flake and Powder Loss;
Contain Spills;
Cleanup Swiftly and Effectively; andDispose of Pellets, Flakes and Powder Appropriately

Company Name: _______________________________________________________________
Department/Crew: _____________________________________________________________
Employee Name: _______________________________________________________________
Signature: _______________________________________ Date: ________________________

Plastics Industry Association (PLASTICS)
1425 K Street, NW
Suite 500
Washington, DC 20005-3686
plasticsindustry.org
npe.org

American Chemistry Council
700 2nd Street, NE
Washington, DC 20002
americanchemistry.com