Task/Plant/Process Risk Assessment Form B 304-1

Date Conducted: Risk Assessment Name & ID: Business Unit: Site:
Jason Tran VISY Beverage Smithfield
Plant/Equipment/Process: Aluminium Baler
Reason for Assessment: Existing Issues Ongoing
Related Events or Existing Hazards:
Assessment Team: Jason Tran Maurizio Ottaviano Paul Dikha
Signatures:
State Environmental, OHS/Workplace Health & Safety, National Heavy Vehicle Legislation. Core Standards AS/NZS ISO: 31000, 9001, 4801, 14001. Manufacturer’s Manual &
References: Risk Assessment Documents.
ID Item description Risks identified Raw Existing Controls Current Further Action Responsible / Future
Risk Risk Completion date Risk
(L+C) (L+C) (L+C)

VERSION DATE: 11 November 2020 | © VISY 2024 | UNCONTROLLED WHEN PRINTED PAGE 1 OF 23
 A. Entanglement Clothing can get 2+3 LOTO policy in place 2+2 LOTO and SOP 2+1
caught in between to stop baling process training and
Can anyone’s hair, clothing, the baler and before undergoing any documentations to be
gloves, necktie, jewellery,
recycled aluminium
5 PM work.
4 signed by operators.
3
cleaning brushes, rags or
other materials become during the
entangled with moving parts
of the plant, or materials in compressing stage. Installing a lock on the
motion? gate to prevent
unauthorized entry into
the lower areas.

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 B. Crushing Stacked pallets of 3+3 Specialised tools and 3+2 LOTO and SOP is 3+1
damaged cans for ladders are used to required to ensure
Can a person be crushed scrapping could break down the cans personal are trained
due to:
cause a potential risk
6 into the catch bins by a
5 and signed.
4
 Material falling from
the plant? of crashing down layer each, keeping
 Uncontrolled or
unexpected movement from overweight, manual handling Internal audits and
of the plant or its load? especially when staff minimal. monitoring to maintain
 Lack of capacity for
the plant to be slowed, is handling manually. compliance and
stopped or
immobilised?
traceability.
 The plant tipping or
rolling over?
 Parts of the plant
collapsing?
 Coming into contact
with moving parts of
the plant during
testing, inspection,
operation,
maintenance, cleaning
or repair?
 Being thrown off or
under the plant?
 Being trapped beneath
the plant and materials
or fixed structures?

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 C. Cutting or Stabbing After the baling 2+3 Resistant gloves are 2+2 SOPs required to 2+2
process, the edges available onsite and ensure all staff are
Can anyone be cut, stabbed and corners of the always worn at all trained and signed for
or punctured due to:
aluminium bales are
5 times. Policies in place
4 compliance.
4
 Coming into contact
with sharp or flying very sharp and could to always have gloves
objects?
 Coming into contact cut/stab skin. on their side.
with moving parts of
the plant during
testing, inspection,
operation,
maintenance, cleaning
or repair of the plant?
 The plant, parts of the
plant or work pieces
disintegrating?
 Work pieces being
ejected?
 The mobility of the
plant?
 Uncontrolled or
unexpected movement
of the plant?

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 D. Shearing Conveyor belt can be 2+3 Gloves are to be worn 2+2 SOPs and LOTO 2+2
jammed from excess during maintenance to training to be signed
Can anyone’s body parts be aluminium and reduce further injury. by all staff.
sheared between any two
particles clotting
5 Policies in place for all
4 4
parts of the plant, or
between a part of the plant under the gears. personnel to have
and a work piece or
structure? Potential risk of injury gloves with them at all
when undergoing times.
maintenance.
LOTO to prevent the
baler from operation
until work is finalised.

E. Friction
Can anyone be burnt due to
contact with moving parts or
surfaces of the plant, or
material handled by the
plant?

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 F. Striking A person’s head can 3+2 Baler is manually run 2+1 2+1
be struck from the to allow operators
Can anyone be struck by bales coming out into complete control over
moving objects due to:
the recycle bins if
5 the baling process.
3 3
 Uncontrolled or
unexpected movement they come too near, Operators ensure that
of the plant?
 The plant, parts of the or if the bins are the area is clear before
plant or work pieces overfilled and not starting the process.
disintegrating?
 Work pieces being under supervision.

ejected?
Mobility of the plant?
Warning signs and
guardrailing in place to
prevent any outside
incidents from
occurring.

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 G. High Pressure Hydraulics 2+4 Protective boots and 2+3 Maintain the servicing 2+3
Fluid or Air underneath the PPE are always worn done weekly/monthly
feeding area 6 as a standard practice. 5 through SOP training, 5
Can anyone come into produces waste oil Regular inspections checklists and toolbox
contact with fluids under
high pressure, due to plant and hydraulic fluids are run and PM talks.
failure or misuse of the during the baling servicing are done to
plant?
process. Will come keep waste minimised.
into contact for
regular cleaning and
maintenance.

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 H. Electrical Hydraulic fluids, 3+2 Fan generators are 3+1 3+1
medicinal oils and installed for cooling off
Can anyone be injured by gases are connected the compressor while
electrical shock or burn due
closely to the plant
5 in operation. An alarm
4 4
to:
 The plant contacting and PLC, electrical system is in place if
live electrical
conductors? conductors are wired the hydraulics go over
 The plant working in to pump the critical limit to notify
close proximity to
electrical conductors? compressor and may staff to stop the
 Overload of electrical induce electrical process.
circuits?
 Damaged or poorly haywire if there is a
maintained electrical
switches?
malfunction.
 Water near electrical
equipment?
 Lack of isolation
procedures?

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 I. Explosion The hydraulic 4+3 PPE and protective 4+2 Installing a lock or at 3+1
compressor can glasses are available least placing caution
Can anyone be injured by break down due to on site, Alarm system signs near the gate to
explosion of gasses,
overexertion or
7 is in place if the
6 prevent unauthorized
4
vapours, liquids, dusts or
other substances, triggered overfilling of hydraulics go over entry in the lower
by the operation of the plant
or by material handled by aluminium, which can critical limit to notify areas.
the plant? cause bits of sharp staff to stop the
scraps to fly out of process.
the machine from
pressure and cause
injury.

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 J. Noise Manufacturing/ 3+5 Mandatory hearing 3+2 Ongoing audiometric 3+2
Process noise Protection Policy on assessments as
Can anyone suffer ill health exposure site required
or hearing loss due to 8 5 5
exposure to high noise
levels (for more information PPE such as noise Ensure that approved
on hazards associated with
noise, refer to the Noise cancelling headphones hearing PPE is always
Code of Practice)? and ear plugs are available onsite
available on site.
Site internal audits to
ensure all staff are
adhering to site policy.

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 K. Slipping, Tripping Hydraulics 2+3 Protective boots and 2+2 Maintain the servicing 2+2
and Fall from underneath the PPE are always worn done weekly/monthly
Height feeding area 5 as a standard practice. 4 through SOP training, 4
produces waste oil Regular inspections checklists and toolbox
Can anyone using the plant, and hydraulic fluids are run and PM talks.
or in the vicinity of the plant,
slip, trip, or fall due to: during the baling servicing are done to
 Uneven or slippery process. Coming keep waste minimised.
work surfaces?
 Poor housekeeping, down to the lower
eg, Swarf in the vicinity areas may cause
of the plant, spillage
not cleaned up? slips from wet
 Obstacles being ground.
placed in the vicinity of
the plant?
 Lack of proper work
platform?
 Lack of proper stairs or
ladders?
 Lack of guardrails or
suitable edge
protection?
 Unprotected holes
penetrations or gaps?
 Poor floor or walking
surfaces, such as the
lack of a slip resistant
surface?
 Steep walking
surfaces?
 Collapse of the
supporting structure?

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 L. Suffocation The feeding area for 3+4 Confined spaces 2+3 Requires one person 2+2
all the cans to be dis permits are available to do PM work from
Can anyone be suffocated posed into poses a onsite, can only do inside while another
due to lack of oxygen or
risk of suffocations
7 maintenance work
5 person next to them for
4
atmospheric contamination?
(Refer to the confined from aluminium and while given approval assistance.
Spaces Regulations)
waste contamination from the manager.
inside due to baling Taking breaks to
processes. Inhalation Masks and PPE is ensure the person
of particles and lack available and must be does not work for an
of oxygen if exposed worn at all times. extended period of
for long periods in time.
PM work.

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 M. High Temperature Industrial Hydraulic 2+3 Fluid is stored in 2+2 2+2
or Fire Fluid is used to keep recycled IBCs with
the compressor 5 protective lids to 4 4
Can anyone come into functional in high prevent outside
contact with objects at high
temperature? pressure. It does sources of flame.
Are there
have the potential to
chemicals/substances in the catch fire if it comes MSDS is available
immediate area, which are into contact with a onsite.
highly flammable or fire
sustaining? spark or flame source
when working on the
hydraulic system in
an enclosed space.

N. Temperature
(Thermal Comfort)
Can anyone suffer ill health
due to extremes of change
weather or radiant heat?

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 O. Chemical Storage Aluminium chloride is 1+3 Chemical is stored in 1+2 1+2
used as a chemical recycled IBCs with
Are chemicals stored in such agent to break down protective lids. Thus,
a manner that they cannot
solids that clog the
4 no possibility of it
3 3
be split during normal
operations? compressor. reaching stormwater.
Are chemicals appropriately
bunded or stored?
Are there opportunities for MSDS is available
liquids to reach the storm
water? onsite.
(Any chemicals require a
separate risk assessment
in accordance with the
Hazardous Substances
and Dangerous Goods
Regulations

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 P. Fumes Gasses and particles 2+3 Gasses and pollution 2+2 Warning signs to 2+1
are generated from that was generated advise staff to steer
Can anyone suffer ill health the baling process, gets filtered out with clear of the plant and
or injury due to exposure to:
which can have
5 ventilation to reduce
4 feed area while in
3
 Toxic gasses or
vapours? detrimental health hazardous particles operation.
 Fumes?
 Possible spilt effects if inhaled. reaching outside the
chemical inhalation?
(Refer to the Hazardous
vents.
Substances Regulations)

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 Q. Ergonomics
Can anyone be injured due
to:
 Poorly designed
seating?
 Constrained body
posture or the need for
excessive effort?
 Design deficiency
causing mental or
psychological stress?
 Inadequate or poorly
placed lighting?
 Lack of consideration
given to human error
or human behaviour?
 Mismatch of the plant
with human traits and
natural limitations?

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 R. Manual Handling Staff over reaching 3+2 Specialised tools and 3+1 Always ensure the 2+1
their arms to perform ladders are provided correct manual
Can anyone be injured due their tasks scrapping for safe and ease of handling and posture
to:
aluminium cans.
5 use task handling.
4 is adopted when
3
 Posture and Layout
Stooping where hands
o
pass below mid-thigh
Using their hands working with bulk
o Reaching above rather than the tools pallets.
shoulder height
o Reaching forward provided.
more than 30cm from
body
Manual handling
o Significant sideways guidelines should be
twisting
o Unbalanced or uneven provided and to be
o
lifting or carrying
Awkward grip involved
signed by staff.
 Task and Object
o Is handling performed
for more than one
hour at a time
o Is handling performed
once every five
minutes
o Are forces applied to
move the object other
than lifting?
o Is there a long vertical
distance of travel
(More than 25cm)
o Is the weight of the
object more than 16-
20kg
o Does the object have
sharp edges
o Does it have
unstable/unbalance
contents
o Are slippery
materials/objects
handled
o Is the object bulky or
awkward
(Any manual handling
hazards identified need a
separate risk assessment
in accordance with the
Manual Handling
Regulations)

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 S. Other
Can anyone be injured or
suffer ill health from
exposure to:
 Dust
 Vibration
 Radiation
 Other factors not
mentioned?

T. Air Quality Baling process 2+3 Gasses and pollution 2+2 Warning signs to 2+1
produces fumes and that was generated advise staff to steer
Can the task or process waste particles from gets filtered out with clear of the plant and
generate gases, dust, fumes
oil, hydraulic fluids
5 ventilation to reduce
4 feed area while in
3
or odours in harmful
amounts? and odours that can hazardous particles operation.
Can the task or process be
changed to reduce these be harmful if inhaled reaching outside the
emissions? directly. vents.

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 U. Resource Use Compressed air, 3+1 MSDS for fluids and 2+1 SOP training with 2+1
hydraulic fluid and oils are onsite, all signage required for
What types of energy are lubricant oil used for chemicals are kept operators to comply
used in this process/task?
the baling process.
4 separately in IBCs to
3 with standards.
3
i.e. compressed air, gas,
electricity, diesel, LPG Usage doses are in prevent exposure.
How much water will be the minimum limit as
used as a result of the they are monitored in
process/task?
the PLC and
Are there opportunities to maintained through
reduce the amount of energy
and/or water used? feeding tubes.

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 V. Waste Generation After processing, 2+1 2+1 2+1
bales are stored in
What type of waste is recycling containers
produced in the process?
to be picked up
3 3 3
Are waste produced
hazardous? externally.
Does this waste need
special disposal?
Are there opportunities to
reduce waste in this
task/area?

W. Water
Is there potential for a
discharge to storm water of
stressors; nutrients,
toxicants, nuisance
organisms (algae),
suspended solids, human
pathogens?
Will there be an impact on
wastewater? Is there a
possibility of exceeding site
licence discharge limits?
Is there opportunity to
reuse/capture
wastewater/stormwater?

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 X. Land
Is there potential for land or
groundwater to be
contaminated as a result of
this task/process?

Y. Noise/Community
Can this task or process
generate noise that will
impact the local residence of
the community?
(consider all times of the day
the task or process is
performed)?
Can this task/process
visually impact the
community and/or effect
cultural values?

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 Z. Compliance No lock on the gate, 2+3 2+3 Safety Measures to be 2+1
allowing anyone to in place, such as
Have the relevant enter under the Authorized access only
site/state/country licences
slippery ladder
5 5 or Danger/Wet ground,
3
and associated legislation
been reviewed for relevance until a lock can be
to the task/process?
installed

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Refer to HowTo-VI-VMS-001 Risk Management How To for further information or guidance conducting risk assessments.

CONSEQUENCE: SAFETY ENVIRONMENT PROPERTY LOSS & SECURITY

INSIGNIFICANT (1)  No injuries or illness.  No or minimal E-impact;  No measurable operational impact to the business.
 Recover without intervention;
 Community likely to tolerate without complaint.
MINOR (2)  First aid treatment;  Minor breach of E-procedures, minimal E-impact;  Minor damage, business disruption, and/or
 Short term illness or minor  Minor unnecessary resource use generation of waste; degradation of service, limited to a single area of the
emotional distress lasting 5 days;  On-site release immediately contained; business.
 One off medical visit and return to  Substantiated and isolated complaint that is minor and easily dealt with.
work no restrictions.
MODERATE (3)  Incident requiring medical  Breach of E-procedures, noticeable impact;  Moderate material damage, business disruption
treatment greater than  Remediation in less than 6 months; and/or degradation of production, impact to multiple
examination or x-ray;  On site release contained with outside assistance; areas of the business.
 Illness or emotional distress that  Substantiated multiple community complaints causing minor annoyance
may last longer than 5 days from one-off or intermittent event – minor and easily dealt with.
MAJOR (4)  Notifiable injury to Regulator;  Likely risk of fines. Potential breach of E-regs, licence, Visy E-policy or  Major material damage, business interruption and/or
 Hospitalisation as an in-patient; other public commitment, substantial impact; degradation of service;
 Permanent disability;  Loss of production capability;  Impact to multiple areas of the business;
 Serious illness or emotional  Off-site release with no detrimental effects;  Major Terrorism Act
trauma;  Emergency response may be required;
 Irreversible health effects.  Substantiated multiple community complaints causing minor annoyance
from ongoing or intermittent event or operation – not easily resolvable.
EXTREME (5)  Multiple fatality;  Definite risk of fines, prosecution director liability;  Extensive material damage and/or business
 Fatality.  Remediation required with more than 5 years to recover; interruption;
 Toxic release off site detrimental effect  Serious threat to long-term viability of the company,
 Emergency response likely; i.e. long term or permanent damage to reputation,
 Justified multiple community complaints that result in significant level of major market share loss;
annoyance and/or off-site health impact – requires emergency services  Catastrophic Terrorism Act.
and/or regulator response.

CONSEQUENCE (C)
LIKELIHOOD (L): 1 2 3 4 5
Common or repeated occurrence under normal
ALMOST CERTAIN (5) 5 6 - MEDIUM 7 - HIGH 8 - EXTREME 9 - EXTREME 10 - EXTREME
circumstances
LIKELIHOOD

LIKELY (4) Likely to occur 4 5 - MEDIUM 6 - MEDIUM 7 - HIGH 8 - EXTREME 9 - EXTREME

POSSIBLE (3) May possibly occur 3 4 – LOW 5 - MEDIUM 6 - MEDIUM 7 - HIGH 8 - EXTREME

UNLIKELY (2) Unlikely to occur 2 3 - LOW 4 - LOW 5 - MEDIUM 6 - HIGH 7 - HIGH

RARE (1) May only occur in exceptional circumstances 1 2 - LOW 3 - LOW 4 - LOW 5 - MEDIUM 6 - HIGH

CONSEQUENCE + LIKELIHOOD = RISK SCORE

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