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In the manufacturing and warehousing/logistics industries, intermediate bulk containers are used to effectively move large amounts of cargo. The 200-liter (55-gallon) drums were the main bulk storage option at the time and were replaced by these IBC totes for the first time in 1992. Since then, these containers have swiftly developed into the main mode of delivery and transportation for businesses all over the world.
We’ll examine IBC totes/bulk container design, upkeep, and transportation in detail in this piece. As you can see, general information applicable to all IBC designs will be covered in this article.
What is an IBC Tote?
An intermediate bulk container is defined by the International Organization for Standards (ISO) as primary packaging that satisfies the following requirements:
- Has a 3 cubic meter (3000 liters) or smaller capacity.
- Can be managed mechanically, either with or without devices that are attached or detached.
- Contains pastes, liquids, or solids.
- Is resilient to typical handling and transportation stresses.
Although there is no lower restriction for the size specified in these regulations, the ISO does point out that IBCs smaller than 0.25 cubic meters (250 liters) are uncommon and might need special testing to be deemed suitable. In addition to being a returnable vessel that may be filled repeatedly, an IBC can also be made into a single-use container that is disposed of once the enclosed substance has been transported.
Additionally, it should be mentioned that these standards apply to IBCs that transport non-hazardous commodities. The integrity and safety of the IBC containers are subject to extra inspection under additional requirements for hazardous materials.
Types of IBC Tote Containers
We will examine the types, sizes, and configurations that are typical in the logistics sector to deconstruct the thousands of distinct designs for IBC totes. You can better grasp what is available on the market and how IBCs are utilized in various contexts by going through the explanations of the different kinds of IBC totes & containers and other features.
Materials are transported using one of six main IBC container tank types. These design types are frequently chosen for each application according to environmental considerations and the requirements of the substance to be transported.
- Metal IBC: This design is easy to return because its body is made of metal, usually steel or aluminum, and it folds up when empty.
- Flexible IBC: Made of weaving materials like paper, plastic, or fabric, this design functions similarly to a metal IBC but has a less rigid form factor. It can be folded when not in use.
- Fiberboard IBC: Made of fiberboard, this design is stiff and holds its shape whether it is filled or not.
- Rigid Plastic IBC: Made of various plastics, these containers are always able to maintain their shape and cannot be collapsed.
- Composite IBC: A single outer structure, which may be rigid, semi-rigid, or flexible, is used in a composite design.
- Wooden IBC: This sort of container is always rigid and can be made from a variety of wood materials.
IBC Tote Dimensions & Size
With generally identical base dimensions of 45 inches long by 45 inches broad, IBC sizes vary from 110 to 550 gallons. These containers can be readily carried with other logistical shipments since their base size is set to correspond with the typical size of pallets. Each container’s height will differ according to its unique IBC volume of construction. Because they are evenly divided into 55-gallon barrels, the next conventional size down for bulk material storage, the most popular sizes are 275 and 330 gallons. Additionally, each IBC has two-, three-, or four-way mobility access for pallet jacks or forklifts.
How to Select a Configuration for IBC
As previously stated, examining the safety and handling specifications for the substance to be carried is frequently the first step in choosing an acceptable IBC. This implies that different IBC types can be appropriate for a given application in various circumstances. When deciding on an IBC shipment strategy, manufacturers, distributors, and logistics partners frequently take the following factors into account:
- Distance of shipment
- Method of shipping (air, sea, land)
- weather (temperature, precipitation, etc.)
- Requirements for packing and storing
- Logistics and quantity requirements (stacking, etc.)
- Requirements for the container fleet (returnable versus one-time use)
As part of a standard supply chain loop, an IBC layout can frequently be utilized for a number of years after it is selected. The ability to transport a comparatively big volume of goods with fewer containers to manage is one of the primary advantages of IBC totes/containers over smaller boats.
Attachments and Fittings for IBC Totes
An essential component of the transportation loop is the IBC totes linkage to other pieces of equipment for filling or emptying the vessel. There will be a tap at the bottom of each IBC so that the material may be moved. A variety of fittings, including horsetails, NPT threads, BSP threads, and female and male cams, are available to materials handlers. Examining the design schematics before dealing with a container IBC will help you decide whether fittings and adapters are appropriate for your specific requirements.
Uses of IBC Totes Frequently
IBC totes are utilized in almost every industry that involves the transportation of substantial quantities of materials. Moving large amounts of material between manufacturing, warehousing, and end-user locations is made easy, secure, and dependable using an IBC. Because every sector is different, there are frequently multiple IBC configurations in use at any given place. The following are a few of the most active industries using IBCs:
- Production of chemicals
- Fabrication of semiconductors
- Production of power
- Processing in industry (fuels, lubricants, hydraulics)
- Building
- Treatment of water
- Agriculture, Food, and Drink
- Biotechnology and pharmaceuticals
These firms can benefit from several advantages and economies of scale when they carry bulk products utilizing IBC totes or containers. A business can attain the best possible quality control, operational expenses, and transportation efficiency by using fewer shipments at higher volumes.
How to Maintain and Clean IBC Totes
An IBC totes will be utilized as a returnable vessel and reused for several shipments for a variety of applications, including the usage of food components. Since they are reusable containers, they need to be cleaned after every use to make sure no contamination can degrade the quality of the subsequent filling. Clean-in-place (CIP) and clean-out-of-place (COP) are the two popular cleaning techniques. This just indicates if the container is transported to a different area for cleaning or if mobile equipment will be used to finish the procedure.
CSI Designs lists several suggested practices for cleaning and preserving the quality of IBC totes in this helpful article, including:
- Observe the regulations of inspections.
- Do not overfill.
- Use caution when moving and lifting totes.
When appropriate, use expert cleaning services.
Slowly remove the lids and wrapping.
IBC totes can last for many years if they are properly maintained and inspected regularly. Prolonging these vessels’ usable lives lowers handling and transit expenses.
How to Store and Ship IBC Totes
The majority of IBCs are made to fit in the same area as a typical pallet and shipment, as was previously noted. It takes increased awareness and attention to safety to work with these big containers. Before moving, it’s crucial to make sure that all hoses and attachments are unplugged from an IBC and that a pallet jack or forklift’s forks are correctly positioned beneath the vessel.
IBCs can be safely stored by adhering to suggested best practices. For any IBC you use, always refer to the paperwork and storage guidelines. Some general insights into the IBC shipment and storage procedures can be gained from the following instructions.
- Confirm the U.N. markings. Each IBC has a UN/DOT marking that specifies the maximum weight that may be carried by that vessel as well as the weight that can be stacked. Based on existing load tests, this is the best-starting data to use before making any decisions about shipment or storage.
- Stack height and nesting. IBC totes should only be arranged according to the manufacturer’s suggested arrangement, while they can be kept in a variety of nesting configurations, including two on two. The majority of IBCs are made to stack at least two containers high, and in certain situations, up to four containers high may be permitted. When the vessels are empty and collapsed or have been expressly built for this purpose, the larger quantities are frequently appropriate. Additionally, you will observe that there are distinct stacking quantity guidelines for storage and transit.
- Container Security. It is crucial to adequately lock these containers since they frequently hold liquids and other items that could spill out of the vessel. To collect runoff in the event of a leak, secondary containment facilities are frequently incorporated into warehouse locations where products will be stored. To prevent movement and possible damage, extra care should be taken to keep the containers in place while they are being stored or transported.
- Available space. The number of IBC containers that can be stacked may be restricted by the amount of space available in warehouse locations or vehicles. For instance, many rows of IBC containers stacked two wide and two high can frequently fit within a typical semi-trailer. Based on container volumes and suggestions from the IBC manufacturer and logistics partners, any party planning to send IBC containers can determine the possible space.
These are only a handful of the numerous factors that need to be taken into account when selecting an IBC shipment and storage strategy. Safety should be the primary focus of any study, and manufacturer’s instructions, safety data sheets (SDS), best practices, and legislation should all be reviewed.
Monitoring and Identifying IBC Totes
Keeping track of each vessel’s location is one of the most difficult aspects of managing a fleet of IBC containers. To increase the likelihood that they will be returned, a lot of material suppliers would rent returnable IBCs to their clients. To make sure that empty vessels are being returned on schedule, the supplier frequently needs to follow up with the clients. The firm will have to make an expensive long-term investment in new totes if returnable IBCs are lost throughout the process.
Using long-lasting asset tags with a distinctive barcode is a recommended practice that applies to many sectors. According to the National Association of Graphic and Product Identification Manufacturers (GPI) Industry Standards and Practices Manual, Metalphoto® anodized aluminum is the most resilient printed aluminum substrate on the market. As such, it is the perfect option for IBC labels to guarantee readability for the duration of the vessel’s useful life.
These IBC barcodes can be read before shipment and tracked in the system when linked to a centralized asset management platform. This provides the IBC owner with full visibility into the quantity of containers in manufacturing facilities, customer facilities, and warehousing locations. Businesses can benefit from these returnable tote barcode systems in several ways, including:
- Shorter cycle times
- Simplified adherence to regulations
- Evidence of delivery
- Better IBC maintenance inspections
Conclusion
Because of its size and longevity, an IBC totes & containers are an important and frequently somewhat costly piece of equipment. One of the various strategies that manufacturers and transportation partners can save logistics costs is to properly track these IBC assets. To maximize storage and transportation requirements, choosing the appropriate IBC container is essential. Businesses may extend the life of their totes and save operating expenses by making sure that correct tracking, maintenance, and regulatory compliance are followed. In addition to streamlining logistics, proper labeling and tracking systems help guard against costly cargo being lost or damaged.