This article is part of a series of “Understanding IBC’s” Guides, and you can read Parts 1,2 and 3 on our Case Studies and Guides section of the website.
General Filling Considerations
IBCs are widely used as a key logistical tool for the storage and transportation of liquids and semi-liquids due to their robust nature, stack ability and efficiency in handling large volumes. Industrial Packaging works with many clients in the chemicals, pharma. and food and drink sectors and filling IBC’s is a key process across these industries. But the filling process needs to be planned and implemented carefully, to ensure a safe, efficient and contamination-free fill. Several key considerations should be addressed to optimise the fill process to retain product integrity, meet regulatory requirements and of course, to ensure the safety of staff working on the process.
Long before the fill process starts, make sure that the process has material compatibility, so that the container itself doesn’t degrade as a result of any chemical interaction with the materials it is being filled with. ECOBULK IBC’s by Schutz are designed to meet a variety of technical requirements, so this can be easily addressed, once you are familiarise yourself with the technical capabilities of the IBC’s. If in doubt, liaise with Industrial Packaging to confirm suitability.
Safety considerations are key throughout the IBC filling process, because many products stored in IBCs are hazardous, flammable, or toxic. Static electricity buildup can ignite flammable vapors, so the right measures need to be taken to avoid this. Personal protective equipment (PPE) must be used by operators, and appropriate ventilation systems should be in place. Emergency procedures should be established and regularly tested.
At the start of a fill, the IBC needs to be on an even surface and it’s important that fittings like stirrers and pumps are fixed onto the IBC with the right equipment. Strong vibrations during the fill should be avoided because they cause mechanical damage.
When pipes, valves and filters are being connected, make sure the right supports are in place to avoid dis-connects or equipment damage.
The flow rate and filling method must be carefully managed. ECOBULK IBC’s , for example, are designed for pressure-less filling, emptying and storing. High flow rates can lead to splashing and equipment damage. Generally with ECOBULK it’s better not to pressurise the IBC. A top filling method is used, at atmospheric pressure, through a 6” or 9” opening and allow air to circulate in the container, until the contents reach an ambient temperature. This is essential to avoid deformation as a result of a vacuum created while the product is cooling, so sufficient aeration is essential.
Once this is achieved, you can screw the cap back onto the opening and tighten it securely, with the appropriate wrench, at which point, the IBC is ready to be stored or transported, as required. It’s handy to know that you can buy an original cap wrench for caps DN150/DN225, through Industrial Packaging, if needed.
Tightening Torques for Screw Caps and Plugs.
The Table below gives you insights into the torque needed for leak-proof storage, under normal circumstances (e.g. ambient temperatures etc). It is indicative and assumes also that there are dry conditions for the plugs and bungs.
Fastening Torques for Dip-Tubes
Similarly, this Table of torques also assumes ambient temperature and dry conditions.
Filling Temperature
Temperature control requirements for a fill will depend on the product. Some liquids must be filled below a maximum temperature to maintain their properties or prevent degradation. With ECOBULK IBC’s, the maximum filling temperature may not exceed 70 ºC in HDPE packaging and 60 ºC wit an integrated liner. It’s acceptable to exceed higher temperatures for a short period of time when cleaning and washing the IBC, ready for re-use.
Filling Level
Some products will expand while being stored in an IBC. This can happen as a result of temperature changes that occur during transportation. So, it’s important to leave sufficient headspace, to avoid leakage or damage to the IBC.
It’s essential to refer to the maximum filling capacity specified for UN certified IBC’s. This can be identified in the UN marking and it corresponds with the brimful capacity in Litres.
For Non-Hazardous good, the maximum recommended filling level is 98% and for Hazardous Goods, the filling level is typically as below
Industrial Packaging – The IBC Experts
In conclusion, the IBC filling process needs to be safe and robust, and it needs to meet regulatory standards. Temperatures, filling accuracy, flow control, safety measures and regulatory compliance are all at-play. By carefully addressing these factors, organisations can maintain product quality and comply with industry standards. Industrial Packaging can give customers expert advice on choosing the right IBC for your fill needs.