Free Pre-Start Checklist (Pelletiser) Template

Purpose of the Free Pre-Start Checklist (Pelletiser) Template

A pelletiser is a powerful piece of plant that requires rigorous safety checks before each use. Implementing a consistent inspection process is crucial for preventing incidents and ensuring operational reliability.

This Free Pre-Start Checklist (Pelletiser) Template provides a structured starting point for your organisation to formalise these essential daily checks, helping operators identify and report potential hazards before they lead to breakdowns or injuries.

The primary purpose of this checklist is to provide a documented, repeatable process for verifying the safe condition of the equipment before operation. It guides operators through a series of critical checks covering mechanical, electrical, and safety components.

Consistent use helps to identify developing faults early, prevent unexpected failures, minimise downtime, and most importantly, protect workers from harm. It also creates a tangible record of due diligence, demonstrating a commitment to proactive safety management.

For broader discussions on equipment readiness, our Pre-Start Checks and Plant Maintenance toolbox talk can help reinforce these principles with your team.

How to use the Free Pre-Start Checklist (Pelletiser) Template

This resource is available as a fully editable DOCX file for easy customisation and a print-ready PDF for immediate use. To begin, download the template and open the DOCX version.

You can then add your company branding, specific machine details (make, model, serial number), and site-specific information. It is essential to review and adapt the checklist items to reflect the unique configuration and risks of your particular pelletiser.

Important Note: This template provides a general framework aligned with Australian WHS practice. We strongly recommend you conduct a specific risk assessment on your equipment and customise the checklist to address all identified hazards.

This is not a one-size-fits-all solution.

After customisation, the checklist can be printed for manual completion or integrated into a digital system. For comparison, you can see how a similar structure is applied in our free CNC Router pre-start checklist.

Key Items on the Checklist

While you must customise the checklist, a comprehensive inspection typically covers several key areas:

• Guarding: Ensure all guards and safety covers are in place, secure, and free from damage. Check that any interlock switches are functioning correctly.
• Emergency Stops: Physically test all emergency stop buttons and pull-cords to confirm they cut power to the machine instantly.
• Feed & Discharge Areas: Check for blockages, damage, or excessive wear in the feed hopper, auger, die, and discharge chute.
• Drive System: Inspect belts, chains, and gearboxes for correct tension, lubrication, and signs of wear or damage. Listen for unusual noises during a brief, no-load test run if safe to do so.
• General Condition: Look for fluid leaks (hydraulic, oil), loose bolts, cracks in the frame, and ensure the surrounding area is clean and free of trip hazards. The principles of inspecting machinery are similar across different plant, such as those covered in our pre-start checklist for agitators.

When to use it

A pre-start check should be completed by the operator at the beginning of every shift or before using the pelletiser for the first time on any given day. It should also be performed after any maintenance or repair work has been carried out to ensure the equipment has been returned to a safe operational state. Integrating these checks into daily operating procedures is a key component of effective WHS management systems.

Who should use it

This checklist is designed for use by trained and competent operators who are authorised to use the pelletiser. The person conducting the check must understand the machine's functions and be able to recognise the hazards associated with it, often confirmed through a Verification of Competency (VOC).

Supervisors or managers are responsible for ensuring these checks are completed consistently and that any reported defects are addressed promptly. Defining these roles and ensuring staff have the necessary skills is a core part of your safety obligations.

If your organisation needs support in establishing these frameworks, consider engaging WHS consulting services.

Integrating into Your Safety System

This pre-start checklist is just one part of a comprehensive safety management approach. The findings from these checks should inform your maintenance schedules and can be used as evidence during safety audits.

The checklist works alongside other critical safety documents, such as a Safe Work Method Statement (SWMS) which outlines the high-risk work associated with the machine's operation. For an example of how these documents are structured, you can review our template SWMS for Concrete Truck Operation. By connecting these elements, you create a more robust system for managing risk. For more tools to support your safety program, browse our complete free WHS resources library.