Intermediate bulk containers (also known as IBC tank, IBC tote, IBC, or pallet tank) are industrial-grade containers engineered for the mass handling, transport, and storage of liquids, semi-solids, pastes, or solids.[1] The two main categories of IBC tanks are flexible IBCs and rigid IBCs.[2] Many IBCs are reused or repurposed.
Description
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Rigid IBC tanks
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Rigid intermediate bulk containers are stackable, reusable, versatile containers with an integrated pallet base mount that provides forklift and/or pallet jack maneuverability. These containers can be made from metal, plastic, or a composite construction of the two materials. Rigid IBC design types are manufactured across a volume range that is in between that of standard shipping drums and intermodal tank containers, hence the title "intermediate“ bulk container. IBC totes are authorized per Title 49 CFR codes[3] to be fabricated of a volume up to 3 cubic metres (793 US gal) while maintaining the "IBC" name and their federal shipping and handling permits.
IBC tank capacities generally used are often 1,040 and 1,250 litres (275 and 330 US gal).[4] Intermediate bulk containers are standardized shipping containers often UN/DOT certified for the transport handling of hazardous and non-hazardous, packing group II and packing group III commodities. Many IBC totes are manufactured according to federal and NSF/ANSI regulations and mandates, and are often IMDG approved as well for domestic and maritime transport. Metal alloy IBC tanks are also manufactured according to NFPA and UL142 certification standards for extensive storage of materials labeled as flammable and/or combustible.
Intermediate bulk containers can be manufactured from various materials based on the requirements of the application or service the IBC will be used for. Traditional materials include:
The most widely utilized and known IBC is the limited re-use, caged IBC tote container. Caged IBC totes are composite intermediate bulk containers — a white/translucent plastic container (typically high-density polyethylene) contained and protected by a tubular galvanized steel grid, common. Caged IBC totes are commonly used due to their low cost, wide compatibility, and versatility.
Collapsible IBC tanks
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Collapsible IBC tanks are designed so that they can be folded when needed to save space when empty or used for return transport. They can also be stacked to save storage space. The replaceable plastic bags with a typical volume of 500 or 1000 liters make the container easy to clean and reuse, which is needed for use with food, as strict hygiene regulations must be observed. The space-saving intermediate bulk containers are used in the pharmaceutical, cosmetics and food industries.
Flexible IBC bags
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Flexible IBCA standard flexible intermediate bulk container can hold 500 to 1,000 kg (1,100 to 2,200 lb) and manufacturers offer bags with a volume of 285–2,830 litres (10–100 cu ft).[2]
Flexible intermediate bulk containers are made of woven polyethylene or polypropylene or other heavy polymers. Bags are designed for storing or transporting dry, flowable products, such as sand, fertilizer, and plastic granules. they typically have lifting straps but are frequently handled on a pallet.
Engineered design
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Most IBCs are cube-shaped and this cube-shaped engineering contributes to the packaging, stacking, storing, shipping, and overall space efficiency of intermediate bulk containers. Rigid IBC totes feature integrated pallet bases with dimensions that are generally near the common pallet standard dimension of 1,200 mm × 1,000 mm or 48 in × 42 in (1,219 mm × 1,067 mm). IBC container’s pallet base is designed for universal maneuverability via forklift/pallet jack channels. Almost all rigid IBCs are designed so they can be stacked vertically one atop the other using a forklift. Most have a built-in tap (valve, spigot, or faucet) at the base of the container to which hoses can be attached, or through which the contents can be poured into smaller containers.
The most common IBC sizes of 275 and 330 US gallons fit on a single pallet of similar dimensions to pallets which hold 4 drums (220 US gallons), providing an extra 55-110 gallons of product in the IBC over drum storage, a 25%-50% increase for the same storage footprint. Additionally, IBCs can be manufactured to a customer's exact requirements in terms of capacity, dimensions, and material.
Advantages
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There are many advantages to the engineering and design of the IBC model:
Uses
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IBCs are often used to ship, handle, and/or store:
Acquisition and disposal
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Intermediate bulk containers may be purchased or leased. Bar code and RFID tracking systems are available with associated software.
An IBC can be purchased as a new unit (bottle and cage), a rebottled unit (new bottle and washed cage) or a washed unit (both bottles and cages have been washed). A washed unit is typically less expensive, with the new unit being the most expensive, and the rebottled unit near the mid-point. In many cases, a customer may purchase a mix (“blend”) of these types of units under a single price, to simplify the accounting.
The customer's choice of unit primarily depends on either actual or perceived sensitivity of their product to contamination, and the overall ability to clean their specific product type from the bottle. Those with a lower contamination risk are prime candidates for the washed units. With the exception of products produced in "clean rooms" (GMP - good manufacturing practices), the decision of a washed over a new is usually a matter of availability or appearance.
An IBC can be leased in a closed-loop (using only the IBCs which were used by a given customer and washed or rebottled) or the most common open-loop system (where the origin of the rebottled or wash unit is flexible). For plastic composite units, the trip lease[further explanation needed] has largely been replaced by a blended purchase. Single use flexible IBC's such as those used for aggregate transportation in the construction industry are a major source of plastic pollution. Most aggregate suppliers do not offer a scheme to refund a deposit upon return of empty IBC's and in the UK they are frequently fly tipped and seen abandoned roadside.
Safety
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When exposed to fire as in a warehouse event, plastic IBCs containing combustible or flammable liquids can melt or burn fairly rapidly, releasing their entire contents and increasing the fire hazard by the sudden addition of combustible fuel. Rigid plastic (as high-density polyethylene) IBCs that transport and house flammable/combustibles are recommended to have clear labeling and stored within properly secured structures and according to federal regulations, such as NFPA and OSHA.[5] Metal IBCs (as carbon steel and stainless steel) are often approved per UL 142 requirements for housing these materials long term. Accordingly, metal IBC tanks can be used for Class I materials, while rigid plastic IBCs can be used for Class II/III materials.
Concerning the mechanical stability and sloshing of intermediate bulk containers during transport, some research has been performed through the U.S. Department of Transportation which seems to indicate that IBC containers perform overall very well during transit in terms of sloshing and mechanical stability.[6]
For metal IBCs, test reports by the German Bundesanstalt für Materialforschung und -prüfung (BAM) show that a metal IBC can withstand fire for at least 30 minutes, if it is equipped with a pressure venting device.[7]
History
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The concept of the IBC was patented in 1992 by inventor Olivier J. L. D'Hollander working for Dow Corning S.A.[8] It was inspired by the patent of a "Fold up wire frame containing a plastic bottle", patented in 1990 by Dwight E. Nicols for Hoover Group, Inc.[9]
See also
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References
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Further reading
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There is no question that having an adequate supply of water following a disaster or other emergency is paramount to both our health and our comfort. A large water barrel or two, if stored properly, will serve you, but don’t forget the storage of bottled water, frozen jugs of water in your freezer (which will them become a makeshift cooler when the power goes out), and water purification and filtering systems. Redundancy in preparedness plans is good and even more so when it comes to water.
Water is one of those things that we don’t think about very much until there’s a shortage. Then, it’s surprising how much water is needed every day. Depending on the number of people in your family and whether you have located, or set aside, a separate water source for hygiene and cleaning, plan on storing between one and three gallons of water per person per day.
Water should be stored in UV-resistant, food-grade plastic containers. Large quantities of water can be stored in an intermediate bulk container (IBC). This is a large plastic container, primarily composed of HDPE, that holds 275 gallons inside a steel cage attached to a steel/plastic pallet. IBCs are easy to fill from the top, and they have a big ball valve on the side at the bottom for FAST draining.
The 55 gallon drum is about the largest container that can be handled by one person when it’s empty. Typically, plastic drums that are suitable for bulk water storage are blue in color, which indicates a food-grade HDPE resin that also blocks UV light. Natural- and white-color drums are probably food-grade, but may not be UV-resistant. Black plastic drums may not be food-grade.
For smaller containers used to dispense the water, use new polyethylene plastic bottles or jugs. Five-gallon jugs are a handy size for transporting your water from bulk storage to kitchen or bathroom. They stack neatly, or you can lay them down on a shelf and use an inexpensive faucet to dispense the water.
Always use new containers for water storage; polyethylene containers can absorb small amounts of whatever was previously inside, and even the most thorough cleaning is no guarantee of purity. Avoid milk or juice bottles; from the get-go, they were intended for only one use, and they won’t hold up. Also, it’s impossible to remove all of the residues from used polyethylene bottles, risking contamination.
Repurposed soda or juice bottles made from PETE plastic (recycling symbol #1) make good water dispensing containers – they just don’t hold very much, but they’re OK at the kitchen or bathroom counter. Just be sure to rinse them well beforehand with a mild bleach solution. This will eliminate any lingering residue and odor.
Wash your containers (even new ones) before using for the first time. Some people prefer bleach – pour two ounces of 5%-9% unscented bleach and three gallons of water into the drum. Close it with a bung wrench (you remembered to order one, right?), and roll and tumble it so all the interior surfaces get wet with bleach water. Then, open the drum up and get rid of the bleach water (down the drain, not on your lawn or flower beds!). Wear goggles when you’re doing this! Let it drain and air-dry, or rinse it with previously purified water.
Choose the permanent storage spot. A filled drum weighs about 500 pounds, so it’s not going anywhere. Drums can be stored vertically, or horizontally on racks. Pick a cool place, out of direct sunlight. Also, this is the time to think about how you will get the water OUT of the drum. Horizontal drums are easy to drain using a simple faucet. If your drums are stored standing up, you’ll need a food-grade pump, and there are lots of choices. If the drums will be in the open, be sure to cover them to keep rain and dirt off the top. This will save you a lot of time and effort.
Fill your containers with a hose made for drinking water. Common garden hoses, even new ones, may contain chemicals or lead that you don’t want in your stored water. Drinking water hoses for boats and campers are made with food-grade materials.
Does water expire? Water does not "expire". However, water can become chemically or biologically contaminated, if stored or handled improperly, but pure water doesn’t go bad or spoil. Still, it’s a good idea to rotate your stored water every six months. Label the containers as “Drinking Water” and include a date so you’ll know when to rotate supplies. Water that’s been stored a long time can become flat and taste stale; you can bring it back by vigorously stirring it or pouring it from one jug to another. This will dissolve some oxygen into the water, freshening it. If there’s any question about the cleanliness of stored water, it can be purified with purification tablets, or a filtering system.
Worried about water security? You can make your water storage drums tamper-evident, or virtually tamper-proof, with locking devices that prevent unauthorized or undetected tampering. They open and close easily, and offer peace of mind when your drums are stored outdoors.