Polystyrene Processing — Training

Before you start

Read all 14 sections, tick the eight safety acknowledgements, then sign the declaration. Your place is saved as you go.

Your full name * Employee / payroll number Job title / role

Section 1 of 14

Purpose, scope and responsibilities

This manual establishes the minimum safe system of work for receiving and processing expanded polystyrene (EPS) and approved polystyrene feedstock using Recycle Group’s hot-melt and cold-compaction lines. It is designed for induction, task training, refresher training, supervision, audit and competency sign-off within the eCheck framework.

Important

This manual is a site procedure and training framework. It must be checked against the exact GreenMax MARS 100-series and Apollo-series manufacturer manuals, electrical drawings, guarding arrangements, extraction design, fire risk assessment, EPA permission conditions and the site emergency plan before issue as a controlled document.

Scope: collection receipt, inspection, storage, forklift rotation, manual feeding, conveyors, granulation, hot melting, cold compaction, cooling, palletising, wrapping, storage, cleaning, jam clearing and maintenance.

People covered: employees, labour hire, contractors, supervisors, forklift operators, maintenance personnel, visitors and delivery drivers entering the operating zone.

Excluded work: electrical work, guard bypassing, confined-space entry, welding/hot work, major repairs and any task not covered by an approved permit or manufacturer procedure.

No productivity target overrides a stop-work decision, guarding requirement, exclusion zone or emergency instruction.

Role	Minimum responsibilities
Site Manager	Provide safe plant and systems; approve risk controls; ensure resources, fire controls, ventilation, maintenance and licensed operators; stop operations where controls are inadequate.
HSEQ / Safety Representative	Maintain risk assessments, training records, inspections, incident investigations, environmental controls and review schedule.
Shift Supervisor	Confirm authorised operators, pre-starts, housekeeping, exclusion zones, stockpile limits, fire equipment access, ventilation operation and safe handover.
Machine Operator	Conduct pre-start; follow this procedure and machine manual; inspect feedstock; remain at controls; stop for abnormal conditions; never bypass guards or reach into moving plant.
Forklift Operator	Hold the required high-risk work licence; complete pre-start; follow traffic plan; maintain load stability and pedestrian separation; place pallets only in designated areas.
Spotter / Second Person	Remain outside danger zones; control access; assist communication; never stand between moving plant and fixed objects or beneath raised loads.
Maintenance / Electrician	Undertake only authorised work under isolation, lockout and verification; restore guards and test safety devices before release.
All Workers	Use PPE, report hazards, protect emergency access, follow signs and stop work if unsafe.

Section 2 of 14

Process overview and approved feedstock

Recycle Group receives polystyrene from councils, transfer stations, businesses, universities, hospitals, commercial customers and the public. Material may arrive in approximately 1 m³, 2 m³ or 3 m³ bags, loose loads, or in a converted approximately 33 m³ hook-bin/container. At North Geelong, incoming material is inspected, placed into the unprocessed-polystyrene holding system and rotated or handled using a Komatsu 3-tonne forklift.

Stage	Hot-melt line — GreenMax MARS 100 series	Cold line — GreenMax Apollo series
Feed preparation	Approved EPS is manually removed from the holding bin and placed onto the feed conveyor.	Approved EPS is manually removed from the holding bin and placed into the designated feed system.
Size reduction	Machine granulates/crushes EPS before heat processing.	Machine granulates/crushes EPS before mechanical compaction.
Densification	Heated extrusion/melting produces dense hot blocks/cubes. Site reports product temperature can exceed 220°C; exact operating temperatures must follow the manufacturer settings.	Mechanical compaction typically reduces volume without a hot-melt stage. Site target is approximately 40–50:1, subject to feed quality and manufacturer specification.
Typical target	Approximately 90:1 volume reduction, subject to feed quality and machine settings.	Approximately 40–50:1 volume reduction, subject to feed quality and machine settings.
Finished product	Cooled blocks/cubes are palletised on a plastic pallet with cardboard base/top, wrapped, re-wrapped and transferred to a holding area.	Compacted logs/blocks are secured, palletised or stored in the approved format and moved to the finished-goods area.

Feedstock rule

Only feedstock approved for the particular machine may enter the line. Unknown plastics, batteries, aerosols, gas cylinders, liquids, medical waste, chemicals, food contamination, metal, timber and other foreign objects must be removed and quarantined.

Section 3 of 14

Operating zones, access and PPE

The polystyrene processing area is a designated yellow zone. Entry is restricted to inducted personnel and authorised visitors under escort. Floor lines, barriers and signs must clearly separate pedestrians from forklifts, conveyors, hot discharge points and rotating pallet wrappers.

PPE item	Hot-melt	Cold-compaction	Notes
High-visibility clothing	Mandatory	Mandatory	Close-fitting; no loose drawstrings.
Safety footwear	Mandatory	Mandatory	Steel/composite toe; slip-resistant sole.
Eye protection	Safety glasses; face shield for hot discharge/handling where splash or ejection risk exists	Safety glasses; face shield if ejection risk exists	Prescription glasses alone are not safety glasses.
Hearing protection	Mandatory where posted or assessment requires	Mandatory where posted or assessment requires	Must match site noise assessment.
Hand protection	Heat-resistant gloves for hot product; cut-resistant work gloves for cool EPS/pallets	Cut-resistant/grip gloves	Gloves must not be worn near unguarded rotating parts where entanglement could occur.
Body protection	Long sleeves and long trousers; heat-resistant apron/sleeves where risk assessment requires	Long sleeves and long trousers	Avoid meltable loose synthetic outerwear near hot product.
Respiratory protection	Only if required by air monitoring/risk assessment; not a substitute for extraction	Only if dust assessment requires	Fit testing, clean-shaven seal area and cartridge selection are required where tight-fitting RPE is used.

PPE is the last line of defence

Guards, interlocks, barriers, extraction, temperature controls, traffic separation and isolation must remain the primary controls.

Section 4 of 14

Hazards and required controls

Hazard / event	Possible harm	Required controls
Hot polymer, die, discharge chute and heaters	Severe burns; ignition; molten material contact	Fixed guarding and shields; hot-surface signs; controlled cooling area; heat PPE; tools for handling; no hand contact; immediate isolation for leaks or uncontrolled extrusion.
Thermal decomposition / fumes	Eye and respiratory irritation; toxic decomposition products during overheating or fire	Local exhaust ventilation; correct temperature controls; no PVC/unknown plastics; investigate smoke/odour; stop and isolate on abnormal fumes; evacuation for fire or uncontrolled smoke; air monitoring as required.
Combustible EPS stock and dust	Rapid fire spread; smoke; environmental harm	Stockpile limits and separation; clear aisles; no smoking/ignition sources; clean motors and floors; fire risk assessment and emergency plan; keep extinguishers/hose reels/sprinklers accessible.
Conveyor nip and draw-in points	Crush, amputation, entanglement	Fixed/interlocked guards; emergency stops and pull wires; close-fitting clothing; tie hair; no reaching, climbing or riding; isolate before clearing.
Granulator / compactor	Crush, cutting, ejection, stored pressure	Interlocked access; secure hoppers; never defeat interlocks; isolate and verify zero energy before access.
High-voltage electrical system	Electric shock, arc flash, fire	Closed electrical panels; authorised electrician only; dry area; inspect cables; isolate at main disconnect; test for dead where required; report trips rather than repeatedly resetting.
Forklift and pallet movement	Collision, crush, dropped load, tip-over	Licensed and familiarised operator; traffic plan; barriers; exclusion zones; speed limits; seatbelt; stable loads; forks lowered during travel; no pedestrians in wrapping/loading zone.
Rotating pallet wrapper	Entanglement, struck-by, crush	Marked exclusion zone; guarded drive; emergency stop; no entry while rotating; secure loose film; isolate before intervention.
Manual handling	Strain, cuts, fatigue	Keep loads small; use team lifts/mechanical aids; rotate tasks; maintain good access; avoid overreaching into holding bin; supervisor sets safe retrieval method.
Slips, trips and blocked exits	Falls; delayed evacuation	Continuous housekeeping; remove pellets, film, straps and cardboard; keep aisles, exits, panels and fire equipment clear.
Contaminated feedstock	Fire, chemical exposure, equipment damage	Receiving inspection; quarantine area; rejection criteria; do not process unknown, wet, chemically contaminated or mixed material.
Noise and heat stress	Hearing loss, dehydration, fatigue	Noise controls/hearing protection; ventilation; cool drinking water; breaks; monitor symptoms and workplace temperature.

Section 5 of 14

Daily pre-start requirements

The authorised operator must complete and record the pre-start before energising either line. Any failed critical item means the machine is tagged OUT OF SERVICE until corrected and released by an authorised person.

Work area, exits, electrical panels and fire equipment are unobstructed.
Unprocessed and finished stock is within marked limits and separated from ignition sources.
Guards, covers, doors and interlocks are fitted, closed and undamaged.
Emergency stops, pull wires and stop controls are accessible and function-tested in accordance with the manufacturer procedure.
Conveyor is correctly tracked and free from material build-up at nip points.
Extraction/ventilation is operating and discharge paths are clear.
No unusual damage, loose fasteners, exposed wiring, leaks, burnt residue or overheated components are present.
Temperature controllers, alarms and displays appear serviceable; settings match the approved recipe.
Hot discharge cooling zone, tools, heat gloves and barriers are ready.
Forklift and pallet wrapper pre-starts are complete; pedestrian barriers are in place.
Correct empty pallet, base/top cardboard and wrapping film are available without blocking access.
Feedstock has been inspected and quarantine containers are available.
Communication method and emergency arrangements are understood by the operating team.

The separate Daily Pre-start record captures these items plus the hot-melt-specific and cold-compaction-specific checks, with defect details and a photo required on any failure.

Section 6 of 14

Receiving and storage

Before unloading, direct delivery vehicles to the designated area and prevent pedestrians entering the forklift zone.
Inspect bags, loose loads and hook-bin/container contents from a safe position. Look for smoke, heat, odour, liquids, batteries, cylinders, aerosols, chemicals, food waste, medical waste, metal and mixed plastics.
Reject or quarantine non-conforming material. Do not manually rummage in unstable loads or enter a bin/container without an approved safe method.
Use the Komatsu 3-tonne forklift only by a licensed, site-authorised operator. Confirm the attachment, capacity plate and load are suitable.
Transfer or rotate material into the holding bin without personnel standing beneath, beside or between the load and fixed structures.
Keep storage below site-approved limits. Maintain fire breaks, access lanes, wall/ceiling clearances and separation from hot machinery according to the site fire risk assessment and EPA conditions.
Record the source, estimated volume, contamination and any rejected material in eCheck.

Section 7 of 14

Hot-melt operation — GreenMax MARS 100 series

Authorised operators only

The exact start-up sequence, temperatures, warm-up times, motor loads, alarm codes and shutdown sequence must match the installed machine manual and approved settings. The steps below provide the site safety sequence, not a substitute for the manufacturer instructions.

Start-up:

Complete the pre-start, confirm extraction is running and establish the hot-product exclusion/cooling zone.
Confirm the main isolator is ON only after guards are secured and the area is clear. Reset emergency stops only after identifying why they were activated.
Start heaters and ancillary systems in the manufacturer-specified sequence. Allow the machine to reach the approved stable operating range before feeding.
Start granulator and conveyor as directed. Observe from the control position for abnormal noise, vibration, current draw, smell or smoke.
Perform a controlled test feed. Confirm material moves freely and the discharge product is forming correctly before full production.

Normal feeding and processing:

Use only clean, approved EPS. Break down oversized pieces using the approved method away from moving plant; never force material with hands, feet or improvised tools.
Feed at a steady rate that does not overload the granulator, bridge the hopper or exceed motor/temperature limits.
Remain at or within immediate reach of the operator controls. Do not leave the line running unattended.
Continuously monitor temperature, motor load, product appearance, extraction, odour and the hot discharge area.
Use approved heat-resistant tools and PPE to guide or separate hot blocks only from the designated safe position. Keep skin and combustible packaging away from hot product.
Allow blocks/cubes to cool in the designated non-combustible, ventilated zone before close handling, pallet wrapping or storage.
Stop feeding early enough to prevent hot product accumulating at breaks, shift change or shutdown.

Stop immediately when

Smoke, flame, glowing material, strong unusual odour or uncontrolled fumes occur · temperature rises outside the approved range or alarms activate or product chars/discolours abnormally · a guard/interlock fails, an emergency stop is damaged, or a person enters the exclusion zone · the conveyor, granulator, screw, die or discharge blocks, bridges or makes abnormal noise · electrical arcing, repeated tripping, exposed wiring, fluid ingress or a hot electrical smell is detected · extraction stops or ventilation becomes ineffective · any battery, cylinder, aerosol, chemical container, PVC or unknown plastic reaches the feed area.

Normal shutdown:

Stop feed and process the remaining approved material according to the manufacturer purge/emptying sequence.
Stop conveyor, granulator, extrusion and heaters in the specified order. Do not isolate cooling or extraction prematurely where residual heat/fumes remain.
Observe the discharge and machine until temperatures reduce to the approved safe state.
Isolate where required for cleaning. Remove loose EPS and film using approved non-sparking/non-damaging tools or vacuum equipment suitable for the hazard.
Inspect for smouldering residue, overheating, blocked extraction, leaks and build-up. Record faults and production data.
Leave barriers in place around hot parts/product until cool and safe.

Section 8 of 14

Cold-compaction operation — GreenMax Apollo series

Start-up and operation:

Complete the pre-start and confirm discharge space, guards, compaction chamber and collection arrangements are clear.
Start the machine only from the designated control position and in the manufacturer sequence.
Feed clean approved EPS at a controlled rate. Prevent bridging and do not push material past guards or into moving parts.
Monitor granulator/compactor load, noise, vibration, product density and discharge alignment.
Keep hands clear of compacted logs/blocks until fully discharged and movement has stopped. Use approved aids for positioning or breaking product.
Secure finished product against rolling, shifting or collapse before forklift movement.
Stop and isolate for jams, access, cleaning beyond routine external housekeeping or any guard/interlock fault.

Cold-line specific hazards:

Stored mechanical pressure and sudden release of compacted product.
Crush and shear points at the compaction chamber and discharge.
Unexpected ejection where feedstock contains metal, rigid plastics or other contamination.
Dust/static build-up and combustible EPS accumulation around motors and electrical components.
Manual handling of dense finished logs or blocks.

Section 9 of 14

Jam clearing, cleaning and LOTO

Absolute rule

No person may reach through a guard, climb onto the conveyor, enter a hopper, clear a jam, clean internal parts or perform maintenance until all energy sources are isolated, locked, tagged and verified at zero energy.

Press STOP and activate the emergency stop if there is immediate danger.
Notify the supervisor and identify all energy sources: electrical, thermal, mechanical, gravity, pneumatic/hydraulic (if fitted), rotational inertia and stored pressure.
Shut down using the normal controls, then switch OFF the main isolator and all ancillary isolators.
Each person working applies their personal danger lock and tag. Group isolation must use the approved lock box system.
Allow hot components/product to cool to the approved safe temperature. Secure or release stored energy using the manufacturer procedure.
Verify isolation: attempt a controlled start from each relevant control, confirm no movement/energy, then return controls to OFF. Electrical testing is performed only by an authorised electrician where required.
Use approved tools to remove the obstruction. Never use hands where hidden sharp, hot or spring-loaded material may be present.
Inspect for damage and confirm all persons, tools and materials are clear.
Each person removes only their own lock. Restore guards, close panels and conduct a documented safety-device test before controlled restart.
Record the jam, cause, corrective action and any maintenance in eCheck. Repeated jams require engineering review — not routine acceptance.

Section 10 of 14

Palletising, wrapping and storage

Confirm hot-melt blocks are sufficiently cooled and stable before palletising. Do not wrap material that is still generating heat or fumes.
Use an undamaged plastic pallet of suitable capacity. Place base cardboard flat without overhang that could catch on equipment.
Stack blocks/logs evenly, within pallet footprint and approved height/weight. Keep the centre of gravity low and do not climb on the pallet.
Transport to the wrapper with the forklift load low, stable and tilted back as appropriate. No pedestrian may enter the travel or wrapper exclusion zone.
Position the pallet centrally on the rotating wrapper. Lower forks, withdraw fully and park clear before rotation.
Attach film from outside the rotation zone. Start the wrapper and remain behind the barrier/marked line. Never step onto the turntable while it can move.
After the first wrap, stop fully before adding top cardboard. Re-wrap to the approved standard, cut/tuck film safely and apply product identification.
Forklift the completed pallet to the designated finished-goods area. Do not block sprinklers, exits, fire equipment, electrical panels, traffic routes or fire breaks.
Inspect wrapped pallets for heat, instability, damaged film or movement before loading/export.

Section 11 of 14

Fire, smoke, burns, electrical incidents and fume exposure

Fire or uncontrolled smoke:

Raise the alarm, press emergency stop only if safe, and call 000 in accordance with the site emergency plan.
Do not approach burning or decomposing polystyrene and do not breathe smoke. Evacuate upwind to the assembly point.
Only trained persons may use an extinguisher on a very small incipient fire where there is a clear escape route and the correct extinguisher is available. Otherwise evacuate.
Isolate electrical power only if this can be done remotely and safely.
Prevent unauthorised re-entry. Preserve access for Fire Rescue Victoria and provide information on stock volumes, machinery and drainage.
Implement the environmental incident controls for smoke, firewater and contaminated runoff. Notify regulators and stakeholders as required by the site plan and permission conditions.
Do not restart until authorised following investigation, inspection and documented release.

Thermal burn:

Move away from the heat source and call for first aid.
Cool the burn under cool running water for at least 20 minutes as soon as possible. Do not use ice, creams or adhesive dressings.
Do not pull away polymer or clothing stuck to skin. Remove jewellery or loose clothing not adhered to the burn.
Cover loosely with a clean non-stick dressing and seek urgent medical assistance for serious, deep, facial, hand, joint, genital or large burns, or any burn from molten polymer/electricity.

Electrical incident:

Do not touch the casualty or equipment until power is isolated.
Call 000 and use trained first aid/CPR/AED response when safe.
All electrical incidents, shocks, arcing and protective-device trips must be reported and investigated before restart.

Fume exposure:

Stop the process if safe, move the affected person to fresh air and raise the alarm.
Call 000 for breathing difficulty, collapse, confusion or persistent symptoms.
Do not re-enter an affected area until ventilation and atmospheric safety are confirmed by an authorised person.

Section 12 of 14

Housekeeping, inspection and preventive maintenance

Frequency	Required activity	Record
Each shift	Remove EPS around motors, heaters, electrical cabinets and exits; clear film/straps; inspect for heat damage, odour, leaks and blocked extraction.	Operator shift checklist
Daily	Test nominated emergency controls/interlocks per manufacturer guidance; inspect guarding, signage, barriers, pallet wrapper and forklift routes.	Daily pre-start
Weekly	Detailed clean under isolation; inspect conveyor tracking, fasteners, cooling/discharge area, fire access and stockpile compliance.	Weekly inspection
Monthly	Supervisor audit of LOTO equipment, training, fire controls, ventilation, electrical condition, traffic separation and housekeeping trends.	eCheck audit
Scheduled by manufacturer	Service bearings, gearbox, heaters, sensors, granulator, compactor, electrical protection and extraction components.	Maintenance system
After incident/jam/overheat	Engineering/maintenance inspection and root-cause review before release.	Incident / corrective action

Section 13 of 14

Training and competency requirements

Operators are not authorised by attendance alone. They must demonstrate knowledge and practical competence for the exact machine and site conditions.

Training module	Content	Evidence
Site induction	Emergency plan, alarms, assembly point, first aid, yellow zone, traffic plan, environmental duties and reporting.	Induction record
EPS feedstock identification	Approved materials, contamination, quarantine, rejection, fire risks and source records.	Knowledge check + observation
Machine theory	Process flow, controls, alarms, guards, interlocks, temperature/mechanical hazards and manufacturer limits.	Written/verbal assessment
Practical operation	Pre-start, start-up, test feed, normal operation, monitoring, stop, shutdown and housekeeping.	Direct observation
Abnormal situations	Jam response, smoke/fume, overtemperature, power failure, foreign object, emergency stop and evacuation.	Scenario assessment
LOTO awareness / authorised isolation	Energy identification, personal locks, verification and restart controls.	Practical demonstration
Forklift / wrapper	HRWL where required, familiarisation, traffic plan, load stability, pallet placement and wrapper exclusion zone.	Licence + site assessment
Refresher	At least annually and after change, incident, extended absence or unsafe performance.	Refresher record

Section 14 of 14

Prohibited actions and life-saving rules

Life-saving rules

These are non-negotiable. Breaching any one of them can kill or seriously injure.

Never bypass, defeat, wedge open or modify a guard, interlock, sensor or emergency stop.
Never place hands, feet, tools or body parts into a hopper, conveyor, granulator, screw, compactor or wrapper while energy is available.
Never clear a jam or conduct internal cleaning without LOTO and zero-energy verification.
Never process unknown plastics, PVC, batteries, cylinders, aerosols, liquids, chemicals or medical/biological waste.
Never wrap or store hot product that is still generating heat or fumes.
Never operate with extraction off, ineffective or bypassed.
Never allow pedestrians inside forklift or rotating-wrapper exclusion zones.
Never repeatedly reset an electrical trip, temperature alarm or overload without finding and correcting the cause.
Never smoke, vape, grind, weld or create ignition sources in EPS storage/processing areas except under an approved segregated hot-work permit.
Never operate when fatigued, impaired, untrained or unauthorised.

Safety acknowledgements

Read each statement and tick it. All eight must be ticked individually — there is no “select all”.

I understand that only approved EPS may be processed and contamination must be rejected or quarantined. I understand that guards, interlocks, sensors and emergency stops must never be bypassed or defeated. I understand that I must never place my hands, feet, tools or body inside processing equipment while energy is available. I understand that jams and internal cleaning require isolation, personal lockout and zero-energy verification. I understand that smoke, uncontrolled fumes, abnormal temperature, failed extraction or electrical faults require an immediate stop. I understand that pedestrians must remain outside forklift and rotating-wrapper exclusion zones. I understand that hot product must not be wrapped or stored while it is generating heat or fumes. I understand that I may perform only tasks for which I have been trained, assessed and formally authorised.

Final declaration

I confirm that I have received instruction in this procedure, had the opportunity to ask questions, understand my stop-work responsibility, and will operate only within my training and authorisation.

I confirm the declaration above. Sign to confirm

Sign above with your finger or a stylus

Your signature is saved when you press Submit.