Step 1: Plastic Shredding
Purpose: Reduce plastic into pressable material.
- Inspect shredder before use
- Feed plastic gradually
- Stop immediately if jam occurs
- Power off before opening hood
Log: jams, broken parts, maintenance needed.
Travelling On-Country Plastic Re-Production Facility
Operations, Safety & Training Manual
1. Purpose of the Facility
This travelling production facility converts recycled plastic into modular tension beds designed for use in remote and Indigenous communities.
- Reduce plastic waste locally
- Support organic and regenerative growing practices
- Enable community-owned production and income
- Create a repeatable, teachable system that can move between locations
The facility is designed to be mobile, repairable, and bolt-together(no glue, no welding in the final product).
2. Product Overview – Tension Bed System
2.1 What the Bed Is
Each finished bed uses two crossed X-frame leg assemblies, two metal tension rods, and one canvas growing surface. The design packs flat, assembles quickly, and is made for repair and reuse.
2.2 Parts per Bed (Fixed Standard)
This ratio does not change. All counting and inventory is based on the recipe below.
Bed Recipe (Standard)
- 8 long plastic legs
- 8 plastic blocks
- 2 metal rods
- 1 canvas top
Geometry: 1 X-frame = 4 legs + 4 blocks • 1 bed = 2 X-frames
2.3 Visual Parts Identification
Add your photos here for clarity (legs, blocks, rods, canvas, assembled bed).
Image: X-frame legs and blocks (to be added)
3. Mobile Container Setup & Machine Flow
3.1 Container Overview
The container is a mobile, enclosed workshop that houses fixed machinery for processing plastic, forming sheets, and cutting parts. Bed assembly happens outside the container to keep the interior clear and safe.
3.2 Machine Zones (Recommended Layout)
- Zone A — Plastic Intake & Shredding: waste plastic → shredded feedstock
- Zone B — Sheet Forming (Heat Press): shredded plastic → solid sheets
- Zone C — Cooling & Stabilisation: sheets rest to avoid warp
- Zone D — CNC Cutting: sheets → legs + blocks
- Zone E — Parts Storage & Buffer: bins for legs, blocks, and offcuts
3.3 External Assembly Zone
Assembly occurs outside the container for more space, better ergonomics, and safer machine separation.
3.4 Material Flow (No Backtracking Rule)
Plastic moves in one direction only:
- Waste plastic → shredder
- Shred → press
- Press → cool
- Sheet → CNC
- Parts → bins
- Parts → assembly
- Bed → packing / shipping
4. Safety Requirements (Non-Negotiable)
4.1 Required PPE
- Safety glasses
- Heat-resistant gloves (thick, extended grip)
- Closed-toe boots
- Long sleeves and pants
4.2 General Safety Rules
- No loose clothing near machinery
- No hands near moving parts
- Machines off before clearing jams
- Hot plastic and metal: assume hot at all times
- Team lifts for heavy sheets
- Report damage immediately
Start-of-day safety brief is required at every new site setup and before any youth-led shift begins.
5. Production Workflow (End-to-End)
Step 2: Sheet Preparation (Flip Table / Frames)
Purpose: Prepare even sheet material.
- Spread shredded plastic evenly (no peaks, no gaps)
- Trim excess with a sharp, sturdy knife
- Lock frame securely
Step 3: Heat Pressing
Purpose: Form solid plastic sheets.
Standard settings: 190°C • 2–3 hours • ~5,000 PSI
- Insert frame at correct angle
- Apply initial force with safe body position
- Re-jack to maintain pressure as required
- Do not rush the cycle
Step 4: Cooling & Stabilisation
Purpose: Stabilise sheet structure and prevent warping.
- Transfer to cooling press or rack
- Minimum cooling time: 6 hours
- No stacking or bending sheets early
Step 5: CNC Cutting
Purpose: Cut sheets into parts.
- Confirm correct templates loaded
- Secure sheet before cutting (clamps / hold-down)
- Stay clear during operation
- Use dust extraction when routing/cutting
Parts cut: long legs and blocks.
Step 6: Edge Finishing
Purpose: Safety and durability.
- Route or sand all edges
- Remove sharp corners
- Inspect holes and joins
Rule: No unfinished parts move to assembly.
Step 7: Bed Assembly
X-Frame Assembly
- 1 X-frame = 4 legs + 4 blocks
- Bolt securely
- Check alignment and wobble
Final Bed Assembly
- 1 bed = 2 X-frames
- Insert 2 rods
- Tension canvas
- Inspect for wobble or slack
6. Production Counting & Inventory Control
Counting Rule (Put This on the Wall)
Beds possible = MIN(legs ÷ 8, blocks ÷ 8, rods ÷ 2, canvas ÷ 1)
End-of-Shift Log (Required)
| Item | Count |
|---|---|
| Sheets made today | ___ |
| Legs available | ___ |
| Blocks available | ___ |
| Rods available | ___ |
| Canvas available | ___ |
| Beds assembled today | ___ |
| Beds possible (stock) | ___ |
7. Maintenance & Issue Reporting
Each shift must record:
- Machine faults
- Broken tools
- Damaged sheets
- Parts failures
- Suggested improvements
This log travels with the facility.
8. Training & Community Use
This facility is designed so that:
- New operators can learn by watching once
- Skills increase through repetition
- Knowledge stays in community
Recommended Training Approach
- Observe full workflow
- Assist one station
- Run one station
- Lead one full cycle
No step is skipped. Safety and quality checks are mandatory.
9. Mobility & Handover Protocol
When relocating the facility:
- Complete final inventory count
- Pack machines in order of setup
- Secure all tools and templates
- Transfer logs to next site
- Brief incoming operators
The system must arrive ready to run, not re-invented.
10. Guiding Principles
- Build locally
- Teach openly
- Repair instead of replace
- Design for reuse
- Keep the system simple and accountable