Pellet, Flake and Powder Transportation and Packaging

Procedures: Pellet, Flake and Powder Transport and Packaging

Hopper car and hopper truck cleaning, loading, storage and unloading present special resin handling challenges.

Cleaning Empty Hopper Cars and Trucks

• Use air lance to make total pellet, flake and powder removal easier.
• Ensure hopper car and truck cleaning areas have wastewater collection and pellet, flake and powder filtration systems installed.
• Recover all pellets, flakes and powder from wash water.
• Recycle, resell or dispose of collected pellets, flakes and powder properly.

Top Loading Hopper Cars and Trucks

• Operate the conveying system properly to avoid clogging and necessitating the opening of lines.
• If a line must be opened to clear blockage, anticipate the potential for pellet, flake and powder loss and always place a catch pan or tarp under the connection.
• Remove any spilled pellets, flakes and powder from the top of the car/truck before leaving the containment area residual pellets, flakes and powder will fall to the ground as cars are moved outside the plant.

Sealing Loading Cars/Trucks

• Close all outlet caps properly before cars/trucks are moved (and request customers to do the same when returning empties).
• Apply seals on all outlet caps (1/8” stranded steel cable or its equivalent).
• Design or modify loading systems so that transfer lines can be completely emptied, with any residual resin being discharged into a container after loading is completed.

Storing at Intermediate Sites

• Consider exposure to vandalism when selecting sites.
• Establish security procedures as necessary (e.g. fencing and lighting).
• Advise companies to report any incidents (e.g. shippers, railroads, trucking companies and processors).

Unloading Hopper Cars and Trucks
Valve Opening

• Contain any possible spill during hook-up by placing a catch pan under the unloading valve before opening.
• Purge unloading tubes within containment area.
• Keep area swept up or vacuumed.
• Consider installing connecting hoses equipped with valves that will close automatically when the connection is broken. Clogged hoses, material bridging in outlets, etc., can require unloading lines to be opened, which presents the risk of spillage.
• Anticipate the potential for pellet, flake and powder loss before opening the line.
• Place pellet, flake and powder disposal cans at rail yards for loading and unloading.
• Have a catch pan or tarp ready to catch pellets, flakes and powder.
• Immediately clean up and properly dispose of any spilled pellets.
• Surges in unloading lines can cause pellets, flakes and powder to be vented into the environment. To prevent this, install a bag house, filter bag assembly or other control device at the unloading system vent.

Completing Unloading

• Ensure that the car/truck is thoroughly unloaded.
• Cycle the outlet valve while air is flowing.
• Visually confirm that each compartment is empty.
• Purge the line before disconnecting.

Sealing Valves

• Close all valves.
• Secure outlet caps and top hatches.

Sampling

• Conduct sampling only in areas protected by containment equipment.
• Review procedures for taking samples to eliminate any possible spillage.
• Use wide-mouth containers or poly-bags for samples.
• Use a funnel collection system to effectively channel pellets, flakes and powder into containers.

Sampling from unloading tubes:

• Place a catch pan or heavy duty tarp under the outlet before opening to catch any spills. (Several commercial devices have been developed specifically for preventing spills during sampling.)

Sampling from top hatches:

• Exercise extra caution to avoid spillage, which can also pose a slipping hazard.
• Close hatches and apply cable seals to prevent access by vandals.