Operation Clean Sweep preventing pellet loss

Procedures: Spills and Packaging


  • Exercise caution to avoid spillage.
  • Clean up any spills immediately.


Using the proper packaging, filling and material-handling procedures can go a long way in minimizing pellet loss.

Selecting Packaging Materials

  • Use packaging designed to minimize the possibility of breakage and pellet leakage. Use puncture-resistant shipping containers where possible.
  • Use reinforced bags, such as woven polypropylene bags, and line larger containers with puncture-resistant material.
  • Minimize the use of valved bags, or seal valved bags immediately after filling.

Bags: Filling and Handling

  • Inspect all pallets for protruding nails or broken boards.
  • Use bags that are not easily punctured.
  • Use a heavier weight container/bag if breakage is a recurring problem.
  • Move and stack bags immediately after filling to avoid seepage.
  • Tape leaks or replace leaking bags.
  • Regularly clean up pellets spilled during the filling process. Where possible, select filling equipment designed to prevent pellet loss.
  • Implement warehouse and handling procedures that minimize the chance of pellet spillage.
  • Dispose of collected pellets properly.

Bags: Emptying and Disposal

  • Thoroughly empty bags.
  • Collect, handle, store and transport the empty bags to avoid/contain the escape of pellets.
  • Recycle plastic resin bags, shrink-wrap and stretch-wrap, whenever possible. Click here 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 spilled during the filling process.
  • Dispose of collected pellets properly.

Improve Palletizing Methods

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

Handling Materials

  • Forklift operators must be trained and skilled in damage prevention as well as 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. 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.
  • Inspect pellet packaging before offloading, particularly pellets bagged in unreinforced paper or corrugated bulk boxes. This will prevent pellet release through the gap between the vehicle and the loading dock.


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

» PDF Version: Operation Clean Sweep Program Manual

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