Best Practices in PET Recycling

Click here for printable PDF version

Safe Debaling Methods

 

Issue: In many cases, debaling of post-consumer PET bottles is performed by automated equipment at the front end of an auto-sort line.  In other instances, bales are broken manually.  Proper safety procedures and employee protective equipment are essential to maintaining workplace safety.

 

Background: The post-consumer PET bale specifications [link to pet_bp/pbp2-0101.htm#postconbale]are listed in Section 2 within this best practice manual.  In brief, the target physical specifications for bales are: 

 

Dimensions:     30"x42"x48" or 30"x48"x60"

Density:           15-20 lbs./ft3. 

 

Bales should be held together with 10-12 gauge, non-corrosive galvanized metal wire, or other non-corrosive strapping material.  All wires should be wrapped singly in one direction to make debaling easier and safer.  No more than 6 to 8 bale wires should be used that will still maintain bale integrity during loading, shipping, unloading and storage. 

 

The recommended bale densities are within the acceptable density range for most debaling equipment.  Bale densities greater than this can limit the efficiency and throughput of debaling equipment, or can cause possible injury to personnel in manual debaling procedures.

 

Best Practices:  Safety is of utmost importance in manual debaling.  Facility operators must require that employees wear personal protective equipment at all times.  Incoming bottle bales are under extreme pressure.  When bale wires are cut, the expansion force of the bale can snap and recoil the bale wires, causing possible injury to plant personnel.  Generally, bale wires will recoil in the direction they are wrapped on the bale.  Make sure that proper clearances are maintained by plant personnel when manually cutting bales wires.

 

Provide each employee with adequate protective equipment, which may include safety glasses, ear protection, heavy protective gloves, hard hats, and safety shoes.  This should minimize worker injuries from bale wires snapping and exposure to sharp edges, heavy objects, toxic or hazardous materials, or other unknown bale contaminants.

 

The following Occupational Safety and Health Administration (OSHA) requirements apply to debaling operations. OSHA regulations can be accessed online at http://www.osha.gov. They are contained in Title 29 of the Code of Federal Regulations (CFR), Parts 1900-1999.  The CFR is also available in the reference section of some public libraries.  Hard copies can be ordered through the Government Publishing Office at (202) 512-1800. 

 

1)  General employer requirements for personal protective equipment are detailed in the Code of Federal Regulations (CFR) under 29 CFR 1910.132, and include:

 

           a) Hazard assessment, written certification, and equipment selection

           b)   Design of personal protective equipment

           c) Communications to affected employees         

           d)   Proper training

           e)    Proper care and maintenance of personal protective equipment

 

2)  General requirements for eye and face protection are detailed under 29 CFR 1910.133.  This section covers employer requirements, including:

 

    a)    Ensure each affected employee wears eye gear with side protection to avoid hazard from flying objects.  Detachable side protectors (e.g. clip-on or slide-on side shields) meeting the pertinent requirements of this section are acceptable.

      b) Criteria for protective eye and face devices are as follows:   

          1)  Protective eye and face devices purchased after July 5, 1994 shall comply with ANSI Z87.1-1989, “American National Standard Practice for Occupational and Educational Eye and Face Protection.”

           2) Eye and face protective devices purchased before July 5, 1994 shall comply with the ANSI “USA Standard for Occupational and Educational Eye and Face Protection,” Z87.1-1968.

 

3)  General requirements for head protection are detailed under 29 CFR Section 1910.135.  This section covers employer requirements, including:

    a)    Ensure each affected employee wears a protective helmet when working in areas where there is a potential for injury to the head from falling objects.

    b)   Criteria for protective helmets are as follows:

           1) Protective helmets purchased after July 5, 1994 shall comply with ANSI Z89.1-1986, “American National Standard for Personnel Protection Protective Headwear for Industrial Workers-Requirements. “

           2)   Protective helmets purchased before July 5, 1994 shall comply with the ANSI “American National Standard Safety Requirements for Industrial Head Protection,” ANSI Z89.1-1969.

     


4)   General requirements for foot protection are detailed under 29 CFR Section 1910.136.  This section covers employer requirements, including:

    a)    Ensure each affected employee wears protective footgear when working in areas where there is a danger of foot injuries due to falling or rolling objects, or objects piercing the sole, and where such employee's feet are exposed to electrical hazards.

    b)   Criteria for protective footwear:

           1) Protective footwear purchased after July 5, 1994 shall comply with ANSI Z41.1-1991, “American National Standard for Personal Protection – Protective Footwear.“

           2) Protective footwear purchased before July 5, 1994 shall comply with the ANSI standard Z41.1-1967 “USA Standard for Men's Safety-Toe Footwear.”

 

5)  General requirements for hand protection are detailed under 29 CFR Section 1910.138.  This section covers employer requirements, including:

    a)    Required use of appropriate hand protection when employees' hands are exposed to hazards such as those from skin absorption of harmful substances; severe cuts or lacerations; severe abrasions; punctures; chemical burns; and harmful temperature extremes.

    b)   Employers shall select the appropriate hand protection on an evaluation of the performance characteristics of the hand protection relative to the task(s) to be performed, conditions present, duration of use, and the hazards and potential hazards identified.

    

Secondly, training employees in safe techniques for breaking bales and continual and regular reinforcement of these safety procedures is very important.   Although plant design will dictate exact safety procedures, the following guidelines should be followed:

·        Break bales in an enclosed area

·        Require employees wear personal protective equipment when debaling

·        Provide a stable access area and protective railings so employees are not at risk if bale wires suddenly break and recoil

·        Establish and enforce a procedure that positions the employee away from any potential wire recoil

·        Provide a properly sized receptacle for wire disposal so bale wires do not enter the process or become a tripping hazard

·        Maintain cutting tools in sharpened condition to facilitate a quick and safe debaling operation.