How PDM Helped a Leading Rotterdam Petrochemical Producer Build a Future‑Proof Operation Clean Sweep System

Plastic pellet loss has become a critical topic in the European petrochemical industry. For Ducor Petrochemicals, a major polypropylene producer located in the Port of Rotterdam, the issue was increasingly visible in operational performance, environmental responsibility, and regulatory oversight. As a long‑standing partner of Operation Clean Sweep (OCS), Ducor wanted to demonstrate real progress toward zero pellet loss, not only for the sake of minimal compliance but to take the lead in sustainable site management.

To accelerate this transition, Ducor asked PDM to lead the complete Spill Management Project, covering engineering, procedures and behavioural change.

Environmental and Regulatory Context in Rotterdam and the Rijnmond Region

The Rotterdam industrial cluster faces growing regulatory scrutiny regarding pellet loss. As an OCS partner, Ducor adheres to the programme created by PlasticsEurope, which provides checklists, best practices and technical frameworks to prevent pellet leakage. The value of OCS lies in its contribution to environmental protection, safety, regulatory compliance, and operational efficiency.

Pellet loss is monitored by:

• DCMR Rijnmond Environmental Service, responsible for enforcement, inspections and environmental regulations for industrial companies in the Netherlands’ largest petrochemical hub.
• The Plastic Soup Foundation plays an activist role in tracking pellet pollution and evaluating industrial performance.

This regulatory and societal pressure forms the backdrop against which Ducor aimed to establish a quantifiable, verifiable zero‑spill standard.

The Project: Building an Integrated Spill Management System for a Rotterdam Polypropylene Producer

Ducor needed a scalable, site‑wide spill management approach but lacked internal capacity to lead a project of this scope. PDM was asked to assume full project responsibility

The assignment focused on three pillars essential for long‑term pellet control:

1. Technical engineering solutions

2. Standardised procedures and operational routines

3. Mindset and behaviour change across teams

This integrated approach ensured the project would deliver lasting change.

1. Engineering Solutions: Custom‑Made Filters, System Redesigns and Technical Optimisation

PDM began by identifying all critical points in the Rotterdam plant where pellets could escape. Using the official OCS-checklists, the team mapped high‑risk zones and designed tailored engineering solutions.

Key engineering outcomes

• Custom‑designed filter systems and housings, created because suitable market alternatives did not exist.
• Solutions engineered to capture both pellets and microparticles.
• Process optimisations to improve the effectiveness and reliability of existing filter installations.
• Additional design improvements around loading stations, transport systems and plant infrastructure.

The total result: more than thirty technical improvements.

2. Operational Procedures: Embedding Spill Prevention in Daily Workflows

Technology alone cannot guarantee spill prevention; consistency does. PDM and Ducor developed new structured procedures to ensure reliability and day‑to‑day control.

Primary procedural improvements

• Fixed daily and weekly checklists tailored to OCS guidelines.
• Regular filter cleaning cycles to avoid clogging and overflow.
• A dedicated pellet cleaning team for zones where filter systems cannot be installed.
• Use of leaf blowers to clean gravel and low‑pressure areas without compressed air.

These routines now form the operational foundation of Ducor’s spill‑free environment.

3. Behavioural Change: Creating Ownership Culture Among Operators and Maintenance Teams

Sustained environmental performance in the petrochemical sector depends heavily on behaviour. PDM therefore devoted a significant part of the project to fostering an ownership culture among employees.

Behavioural interventions included

• Awareness training on environmental risk, fines, regulatory exposure and reputational impact.
• Introduction of the 24‑hour rule: any spill must be cleaned within one day.
• Better alignment between management and staff, with structured attention to employee-generated technical improvement ideas.

This resulted in a mindset shift across the organization which is essential for long‑term OCS compliance.

Project Results: A Verified Zero‑Pellet-Loss Industrial Environment

The integrated approach delivered measurable results fully aligned with the OCS-standard:

Measurable outcomes

• Over 30 engineered improvements implemented across the Rotterdam site.
• A complete, standardised spill management procedure.
• Structural behavioural change among operational teams.
• A clean site and surrounding area, free from detectable pellet pollution.
• Positive assessments during DCMR inspections, both announced and unannounced.

This makes Ducor one of the leading examples of effective spill management in the Netherlands’ petrochemical sector.

Voice of the customer

“PDM has done a good job implementing the Operation Clean Sweep program, developing technical solutions as well as changing employee behavior.”
 — Operations Manager, Ducor Petrochemicals