Product Overview

Summary: This Plastics Recycling Process Safe Operating Procedure sets out a clear, safe and efficient method for sorting, processing and storing plastic waste in Australian workplaces. It helps you control contamination, machinery hazards and environmental risks while maximising resource recovery and maintaining compliance with WHS and environmental legislation.

This Plastics Recycling Process Safe Operating Procedure is designed for Australian facilities involved in the collection, sorting, shredding, washing, granulating and storage of plastic materials. From council transfer stations and materials recovery facilities through to specialised plastics reprocessors, the document provides a structured, step‑by‑step method for running the process safely and consistently. It addresses the real‑world challenges of handling mixed and contaminated plastic streams, managing high‑risk plant, and working in busy loading and processing areas with mobile equipment.

The SOP aligns with Australian WHS expectations and environmental duties of care by embedding hazard identification, risk control and quality checkpoints into each stage of the process. It supports businesses in reducing contamination and product rejects, preventing injuries from conveyors, shredders and balers, and ensuring appropriate controls for dust, noise and chemical exposure from washing systems. By implementing this procedure, organisations can demonstrate due diligence, improve operational efficiency, and provide clear, practical guidance for training new and existing staff involved in plastics recycling operations.

Key Benefits

• Ensure consistent, safe handling of plastics from receipt through to processed product using clearly defined process steps.
• Reduce incidents and near misses associated with conveyors, shredders, granulators, forklifts and mobile plant.
• Improve product quality by standardising sorting, contamination checks and labelling of plastic grades.
• Streamline training and onboarding for new operators with a single, easy‑to‑follow procedure that reflects Australian WHS requirements.
• Demonstrate compliance with WHS and environmental obligations, supporting audits, customer requirements and regulator inspections.

Who is this for?

• Recycling Plant Managers
• Materials Recovery Facility (MRF) Supervisors
• WHS Managers and Advisors
• Production and Operations Managers
• Environmental and Sustainability Managers
• Line Leaders and Team Leaders
• Maintenance Supervisors
• Plant Operators and Sort Line Operators
• Waste Management Coordinators
• Logistics and Yard Supervisors

Hazards Addressed

• Entanglement, drawing‑in and crushing hazards at conveyors, shredders, granulators and balers
• Struck‑by and run‑over risks from forklifts, loaders and other mobile plant in tipping and storage areas
• Manual handling injuries from lifting, stacking and moving bales, bins and heavy bags of plastic
• Exposure to dust, fumes and microplastics during shredding, granulating and tipping operations
• Chemical exposure and skin/eye irritation from detergents, cleaning agents and process water in washing systems
• Slip, trip and fall risks from wet floors, loose plastic film, offcuts and poorly managed housekeeping
• Noise‑induced hearing loss from continuous operation of high‑noise plant and equipment
• Fire and explosion risks from accumulated plastic dust, flammable residues and hot work near stored plastics
• Biological hazards from contaminated or putrescible plastics (e.g. food containers, medical‑type waste)
• Ergonomic strain from repetitive sorting tasks and awkward workstations along sorting lines

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Process Overview
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Competencies, Induction and Training
• 6.0 Plant, Equipment and PPE Requirements
• 7.0 Pre‑Start Checks and Area Preparation
• 8.0 Receipt and Inspection of Incoming Plastics
• 9.0 Sorting, Grading and Contamination Control
• 10.0 Shredding, Granulating and Size Reduction Procedures
• 11.0 Washing, Drying and Process Water Management
• 12.0 Baling, Packaging, Labelling and Storage of Recycled Plastics
• 13.0 Mobile Plant, Traffic Management and Loading Operations
• 14.0 Hazard Identification and Risk Controls (Mechanical, Chemical, Biological, Ergonomic, Noise)
• 15.0 Housekeeping, Wastewater and Residual Waste Management
• 16.0 Lock‑Out/Tag‑Out (LOTO) and Isolation Procedures for Maintenance and Blockage Clearing
• 17.0 Emergency Procedures (Fire, Chemical Spill, Injury, Plant Failure)
• 18.0 Environmental Considerations and Pollution Prevention
• 19.0 Inspection, Monitoring, Recordkeeping and Continuous Improvement
• 20.0 Document Control and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and corresponding state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: How to manage work health and safety risks
• Safe Work Australia – Code of Practice: Managing noise and preventing hearing loss at work
• Safe Work Australia – Code of Practice: Hazardous manual tasks
• AS/NZS 4024 series: Safety of machinery
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001: Occupational health and safety management systems – Requirements with guidance for use
• Environment Protection (Waste and Resource Recovery) legislation and guidelines as applicable in each state or territory