How We Ensure Zero Pellet Loss: Operation Clean Sweep at Pipelife

Microplastics present a formidable environmental challenge due to their low biodegradability and small size, which makes cleanup efforts difficult. As efforts to understand the full impact of microplastics continue, we explore the causes of microplastic pollution, the legislative and voluntary measures taken to tackle it across Europe, as well as the initiatives implemented at Pipelife’s production sites to eliminate pellet loss.

What Are Microplastics?

Microplastics are very small pieces of plastic, 0,1 µm – 5 mm long. Due to their small size, removing microplastics from the environment once the pollution occurs is highly challenging. According to the European Environment Agency, between 0.7-1.8 million tons of microplastics are unintentionally released into the environment across the EU each year. Microplastics have been found in water bodies, soil, food, drinking water and even the human body. 

Currently, more data are still needed about the potential impacts of microplastic pollution on both the environment and human health; however, the first non-governmental initiatives and legal attempts to reduce and prevent microplastic pollution across Europe have been launched. The EU’s Zero Pollution Action Plan, part of the European Green Deal, aims to reduce microplastic releases into the environment by 30% already by 2030.

Where Do Microplastics Come From?

Most microplastic pollution comes from the degradation of plastic litter that ends up in the environment due to poor waste management. Stricter limits on single-use plastics and plastic packaging, as well as tighter control over waste management processes, are key to limiting this pollution source.

Microplastics are also intentionally added to a variety of commonly used household products, such as cosmetics, detergents, paints and others. Abrasion of car tires, shedding from synthetic fiber textiles, pellet loss, and limited biodegradability of detergent capsules are other common microplastic pollution sources. 

The EU has announced a number of regulations addressing the many sources of microplastic pollution. For example, the REACH restriction requires manufacturers using microplastics in production to report on pellet losses on an annual basis, while the proposed Ecodesign for Sustainable Products Regulation seeks to reduce the environmental impacts of a broad range of widely used products.

What Are Plastic Pellets, And Do They Contribute to Microplastic Pollution?

Pellets are small particles, typically 2-5 mm in diameter, used as raw material for manufacturing plastic products. If the handling of pellets is not done carefully, they can end up in the environment. According to the EC estimations, between 52 and 184 tons of pellets were unintentionally released in 2019. While these figures are significantly lower compared to the microplastic pollution coming from sources like paints and car tires, they illustrate the urgent need to critically examine and improve the current pellet-handling practices.

To stop the loss of pellets into the environment, Plastics Europe, a European association of plastics manufacturers, has come up with the Zero Pellet Loss initiative. In 2015, this initiative was united with the global Operation Clean Sweep® program, and Plastics Europe currently acts as the principal host of Operation Clean Sweep® in Europe.

In addition, the European Union has proposed its own set of measures to curb pellet loss. In April 2024, the European Parliament voted in favor of a regulation on preventing plastic pellet losses.  

What Can Manufacturers Do to Prevent Pellet Loss?

Robert Rogina, International Manager of Standardization and Quality at Pipelife, explains that both OCS Europe and the recently introduced EU-wide regulation stipulate a similar approach to preventing pellet loss along the plastics value chain. Key measures that must be upheld are risk identification and assessment, implementation of preventive measures, employee training, and increased monitoring of pellet management and containment. 

However, while company participation in OCS Europe is entirely voluntary, the EU regulation will be applicable to all businesses handling more than 1,000 metric tons of plastic pellets per year and is expected to enter into force in 2025. Both OCS Europe and the regulation on preventing pellet losses also require businesses to be audited by an independent certification body, yet, it is not clear at this stage whether the two certification schemes would be aligned.

Comprehensive Inspections and Tailored Measures: Achieving Zero Pellet Loss at Pipelife 

Pipelife has committed to ensuring all its production facilities adhere to the highest standards for pellet handling and loss prevention. 

“Our plants have undergone thorough inspections and implemented a wide range of actions to ensure no plastic particles enter the environment,” says Rogina. “These range from relatively simple ones, like sealed collection and storage bins, to advanced solutions, such as automated raw material transfer and a mobile app for immediate spillage reporting.”

Additional groupwide initiatives include the installation of zero-loss containment systems in stormwater drains, ensuring pellets can’t reach wastewater networks and water bodies. Special training has also been provided to staff responsible for containment system maintenance. 

Beyond an online reporting system, all sites are equipped with industrial vacuum systems and sweepers to collect all pellet residues securely in case a leakage occurs. However, priority is given to safe truck unloading and storage of pellets to eliminate spills entirely.  

“Handling pellets manually always means a higher spill risk,” explains Rogina. “We’re proud that our production sites rely on automated unloading of raw material and more than 90% of our total production volume is stored in silos.”

Apart from groupwide measures, certain production sites have also implemented their own tailored steps to achieve zero pellet loss. For example, Pipelife Norway’s plant in Stathelle, located by the sea, stops outdoor cutting processes altogether on days with higher wind speeds. 

Assessing Groupwide Progress and Compliance 

While preventing plastic pellet pollution requires a comprehensive approach, Pipelife’s chosen strategy demonstrates that achieving zero loss is a realistic goal. Rogina emphasizes that the company has committed to have all its business units audited and certified under the OCS scheme. In addition, Pipelife encourages its many collaboration partners to pursue the same goals. 

“All our facilities have been operating in compliance with the zero pellet loss principles. We have reached out to an external auditor, and our target is to have all our plants committed to OCS certification auditing by 2025.”