Product Overview

Summary: This Lockout Tagout (LOTO) SOP sets out clear, step‑by‑step procedures for isolating and de‑energising machinery and plant in recycling facilities before inspection, maintenance or clearing blockages. It is designed to prevent unexpected start‑up, entanglement and crush injuries, while supporting compliance with Australian WHS legislation and due diligence obligations.

Recycling plants operate complex systems of conveyors, balers, shredders, compactors, crushers and sorting equipment that can start automatically or retain stored energy even when switched off. Without a robust Lockout Tagout system, workers clearing jams, conducting maintenance or performing inspections are exposed to serious risks including entanglement, crushing, amputation and fatal injuries. This SOP provides a tailored, plant‑specific framework for implementing LOTO in the noisy, fast‑paced and often congested environment of Australian recycling facilities.

The procedure walks users through pre‑task planning, identification of all energy sources, application of locks and tags, verification of isolation, and safe removal of devices once work is complete. It distinguishes between routine operator tasks and higher‑risk maintenance activities, and clearly defines who is authorised to isolate, who may apply personal locks, and how to manage contractors and multi‑employer worksites. By adopting this SOP, recycling businesses can standardise isolation practices across shifts and sites, demonstrate compliance with WHS Regulations, and significantly reduce the likelihood of catastrophic plant‑related incidents.

In addition to the step‑by‑step method, the SOP embeds practical tools such as isolation point registers, equipment‑specific isolation diagrams, shift handover requirements and group lockbox arrangements for shutdowns. It also addresses common recycling‑sector challenges, such as dealing with build‑ups and blockages, managing remotely controlled and automated systems, and coordinating isolation when mobile plant interfaces with fixed plant. The result is a clear, defensible and easy‑to‑train procedure that protects workers, supports supervisors and reduces downtime from preventable incidents.

Key Benefits

• Prevent serious injuries and fatalities from unexpected start‑up, entanglement and crushing during maintenance and blockage clearing.
• Ensure compliance with WHS Act and WHS Regulation isolation and energy control requirements specific to plant in recycling operations.
• Standardise isolation practices across all shifts, sites and contractors, reducing confusion, shortcuts and unsafe improvisation.
• Reduce unplanned downtime, equipment damage and incident‑related disruptions through controlled, predictable isolation processes.
• Strengthen training, supervision and due diligence evidence with clear documentation, isolation registers and sign‑off requirements.

Who is this for?

• Recycling Plant Managers
• Operations Managers
• Maintenance Supervisors
• Mechanical Fitters
• Electricians
• Production Team Leaders
• WHS Managers and Advisors
• Health and Safety Representatives (HSRs)
• Contractor Coordinators
• Shutdown and Project Planners

Hazards Addressed

• Unexpected start‑up of conveyors, balers, shredders, crushers and compactors
• Entanglement in moving belts, rollers, augers and rotating shafts
• Crush and pinch point injuries from rams, presses and hydraulic systems
• Release of stored mechanical, hydraulic, pneumatic and gravitational energy
• Electric shock and arc flash from live electrical components
• Contact with sharp edges, blades and cutting elements during maintenance
• Struck‑by injuries from moving or falling plant components during isolation or re‑energisation
• Unauthorised or inadvertent removal of isolation devices by other workers or contractors

Included Sections

• 1.0 Purpose and Scope – Application to fixed and mobile plant within recycling facilities
• 2.0 Definitions – Lockout, Tagout, Isolation, Stored Energy, Authorised Person, Affected Person
• 3.0 Roles and Responsibilities – PCBUs, Plant Managers, Supervisors, Maintenance Personnel, Operators, Contractors
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Plant and Energy Source Overview – Typical recycling plant equipment and energy types
• 6.0 Required Lockout Tagout Equipment – Locks, tags, hasps, lockboxes, isolation devices and signage
• 7.0 Pre‑Task Planning and Risk Assessment – JSA/SWMS requirements and permit‑to‑work (if applicable)
• 8.0 Identification of Isolation Points – Use of isolation registers, drawings and equipment‑specific procedures
• 9.0 Step‑by‑Step Lockout Tagout Procedure – Isolation, application of locks/tags, dissipation of stored energy, verification of zero‑energy state
• 10.0 Group Lockout and Shutdown Management – Lockboxes, multiple crews and contractor coordination
• 11.0 Special Considerations for Recycling Plants – Blockage clearing, confined spaces, automated and remote‑start systems, interface with mobile plant
• 12.0 Tagging Requirements – Information to be included on tags and rules for tag use and control
• 13.0 Removal of Locks and Tags – Re‑energisation checks, start‑up warnings and sign‑off process
• 14.0 Management of Abandoned or Forgotten Locks – Escalation, verification and documentation procedure
• 15.0 Training, Competency and Authorisation – Induction, refresher training and competency assessment
• 16.0 Inspection, Monitoring and Review – Audits of LOTO practices, incident reporting and continuous improvement
• 17.0 Recordkeeping – Isolation registers, training records, permits and audit reports

Legislation & References

• Work Health and Safety Act 2011 (Cth and corresponding state and territory Acts)
• Work Health and Safety Regulation 2011 – provisions relating to managing risks of plant and isolation of energy sources
• Safe Work Australia – Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• AS/NZS 4024.1603: Safety of machinery – Design of controls, interlocks and guards – Prevention of unexpected start‑up
• AS/NZS 4024.1201: Safety of machinery – General principles for design – Risk assessment and risk reduction
• AS 1319: Safety signs for the occupational environment