Intermediate bulk container
Intermediate Bulk Containers ( IBC , German: Großpackmittel ) are large cuboid containers for liquid and pourable substances. They are used in the production of chemicals, food, cosmetics and pharmaceuticals.
Depending on the construction and design, the IBCs have a volume of 500 to 3000 liters. IBCs are also approved for the transport of dangerous goods . To do this, however, it is necessary to conduct a repeat examination (WHP) every two and a half or five years .
IBCs with a floor space of around 1 square meter, i.e. the size of a Euro pallet 80 × 120 cm to 120 × 120 cm and around 1 cubic meter = 1000 L filling capacity, are common. Thanks to the integrated pallet made of plastic, metal or wood, these can be easily lifted from a truck with a forklift and moved by hand with a pallet truck on a firm, level hall floor. In comparison, cylindrical drums are not as easy to load and stack, but can easily be rolled by hand with a certain amount of care.
Compared to cylindrical drums , IBCs use the storage space much more efficiently with their cubic design. An IBC with a capacity of 1000 liters takes up as much storage space on a pallet as four steel drums with a volume of 200 liters each. The work is made easier for both filling and emptying, as they only need one work step for 1000 liter products instead of five work steps for 200 liter drums for the same amount. Most IBCs also have the advantage that they can be cleaned after use and thus used several times. IBCs can be moved with forklifts or pallet trucks and are stackable due to their design.
IBCs are often used by hobby gardeners to store rainwater. They can often be bought second-hand cheaply and used for many years.
Combination IBC
The most common IBCs consist of a pallet with a plastic tank and a simple mesh cage or tubular frame. Under dangerous goods law, they are assigned to bulk packaging. The name combination IBC (English: composite IBC), or K-IBC for short, means that the container is made up of an inner container made of plastic and an outer frame made of welded and galvanized metal pipes including a pallet. The inner container (bladder) is cuboid (mostly 1200 × 1000 × 1160 mm) and holds approx. 1060 liters in the standard version. It consists of HDPE (high density polyethylene) and is produced in one piece using the extrusion blow molding process . There are different types of outlet fittings in the floor area for three different sizes (DN50, DN80, DN150). The outer container, also known as a lattice box, is screwed to the pallet (steel, plastic, wood or mixed forms) before it is completed. The cuboid design of the K-IBC guarantees optimal use of the volume, but has a negative effect on cleaning. K-IBCs are also approved for the transport of dangerous goods (UN31HA1 / Y), but irrevocably lose their approval for dangerous goods after five years at the latest. An inspection by a competent inspector is required after 2.5 years. As part of this recurring test, the container is tested in accordance with ADR, Chapter 6.5.6.7.3. According to this regulation, the test must be carried out for at least 10 minutes with air at an overpressure of at least 20 kPa (0.2 bar) {see leaflet for the implementation of periodic tests of the EGI on IBCs [1]}. This regulation is used in other European countries, in Germany it has been changed to such an extent that the test pressure is reduced, i.e. 0.1 bar, in thin-walled constructions where permanent deformation of the outer casing is to be expected after the test {see BAM minutes of the 29th meeting of ERFA-Verpackungen on November 7, 2002 in Berlin [2]}. After being used for the first time, K-IBCs are reconditioned in large numbers by the original manufacturer or a separate branch of industry (reconditioning companies). The bladder can be cleaned or replaced entirely ( reconditioning ).
K-IBCs are also available in different electrostatic versions, which prevent the dangers of static charging of the plastic (K-IBC-EX). This is done either by shielding with a complete metal container, a close-meshed pipe grille or a three-layer coextruded bladder with an outer layer made of conductive or dissipative (antistatic) polyethylene. These containers are also tested for use in explosive atmospheres of zones 1, 2, 21 and 22 and / or flammable liquids of explosion groups A and B with a minimum ignition energy MIE> 0.2 mJ. Since electrostatic charge is generated when filling from above, only conductive liquids ( e.g. ethanol , propanol ) can be safely filled using this method. Safe because the charges generated are discharged via the conductive liquid and the conductive, grounded bottom valve. Non-conductive liquids ( e.g. toluene , hexanes ) can only be filled safely if the generation of charges is minimized by filling below the level . K-IBC-EX must not be used for diethyl ether with an ignition energy <0.2 mJ. The depletion is less charge generating. Stirring in K-IBC-EX should only be carried out after a risk assessment and additional safety measures derived from it in accordance with CENELEC 50404: 2003, BGR132 or the new TRBS (to be published in 2009).
If dangerous goods are shipped on public land and sea routes, the suitability of the plastic used in relation to the filling goods must be proven under transport law ( GGVSE , IMDG Code , BAM ).
Plastic IBC
This less common variant consists of a rectangular plastic tank, but without a metal outer container. The bladder is self-supporting here, so it weighs significantly more and has greater wall thicknesses. They are also available in a combined version with an outer container also made of plastic.
UN packaging code: WA
Metal IBC
Today, metal IBCs are used in almost all branches of industry in the chemical, pharmaceutical and cosmetics industries, in the food and beverage industry, in trade and commerce for the efficient handling of goods. Metal IBCs are usually made of stainless steel , for example 1.4301 or 1.4571. Metal IBCs consist of a stable frame in which a rectangular or cylindrical container is enclosed. IBCs of this type are permanently approved for dangerous goods , provided that the regular inspection is carried out every two and a half years by a specialist. Experts (e.g. TÜV, Dekra) or inspection bodies according to BAM GGR 002 are competent. The cylindrical and cuboid tanks are particularly suitable for tasks that involve frequent changes of products. Since stainless steel is very easy to clean without leaving any residue, these IBCs are also used as aseptic food containers. There is no danger of substances stored in the IBC diffusing in with a stainless steel container (in contrast to the plastic IBC).
If metal IBCs are equipped with devices for pressure relief, they are particularly suitable for storing and transporting flammable substances. Fire tests have shown that such metal IBCs can withstand fire exposure for 30 minutes without bursting.
The period of use (operating times) of metal IBCs is almost unlimited and often reaches over 20 years. On the other hand, according to subsection 4.1.1.15 ADR, the permissible period of use for barrels and canisters made of plastic, rigid plastic IBCs and combination IBCs with plastic inner liner for the transport of dangerous goods is five years from the date of their manufacture, unless something is notified by the competent authority otherwise stipulated or a shorter period of use is not prescribed due to the type of substance to be transported. After the five years in use as a hazardous goods container, plastic IBCs must be withdrawn from circulation.
Metal IBCs can be recycled without any problems. On the other hand, plastic recycling, especially when used beforehand as a hazardous goods container, can prove to be very problematic due to the latent risk of hazardous substances diffusing into the plastic (disposal as hazardous waste).
The acquisition and maintenance costs of the metal IBC are higher compared to a plastic IBC, which in view of the long service life, however, pays off in any case. However, metal IBCs are only suitable for shipping to distant regions if they are integrated into a return system.
Heatable IBC
Another development are electrically heatable IBCs, which are based on the metallic IBC and are used for the transport and storage of temperature-controlled goods. Among other things, it is used to transport and store chocolate, waxes and glue at temperatures of up to 180 ° C. As an alternative to integrated heating, special container heaters can also be used.
Flexible IBC
These are also assigned to bulk packaging under dangerous goods law. FIBC (Big Bag) are used to transport solid, but free-flowing products such as powders or granulates. They always consist of a sewn polypropylene fabric. In some cases, a polyethylene inliner (foil bag) can be incorporated. The large bags can be made very individually in any size. Volumes of 500 to 2000 liters are common. They usually have four hanging loops and are cubic in size. They are also available with approval for hazardous goods and in electrostatically conductive versions. The main advantage is again the better use of space and more economical handling compared to small sacks or rigid drums. In contrast to rigid IBCs, FIBCs can also be bought from far away from low-wage countries, as they are foldable and the transport costs are therefore kept within limits.
The FIBC used in Europe must comply with the ISO 21898 standard, which, in addition to defining the individual components, also contains information on the load capacity (SWL) and the safety factor (SF). A disposable FIBC must have been tested to five times the actual filling weight, and a reusable FIBC to six times. In addition, there are other technical features that are important for handling FIBC in practice. This includes UV stabilization, coordination with the pallet size used, coating, dust tightness of the seams, possibly food-safe and many other aspects.
Foldable IBC
Foldable IBCs have been developed to meet the high hygiene and safety requirements of the food processing industry. They enable the cost-efficient transport and storage of fruit concentrates, fruit preparations, dairy products and other liquid viscous products and recently also for solids such as granulates or tablets. They are based on a foldable plastic container and a sterilized plastic bag (inliner) with an aseptic valve. The inliner is located in the container and can be filled with liquid. The foldable IBC is particularly cost-effective thanks to its stackability, easy foldability and low maintenance requirements.
Reconditioning and Rebottling
The containers are reconditioned for repeated use (thorough exterior and interior cleaning with water, acid or lye, depending on the previous ingredient). The customer has to submit the safety data sheets of the substances with which the container was previously filled. Specialists decide on reuse or disposal. Rebottling is the name given to the renewal of the inner plastic bladder when the cage and pallet are reused.
Web links
literature
- Georg Küffner: Too good to throw away. IBC containers lead a colorful second life . In: Frankfurter Allgemeine Zeitung . No. 286 , December 9, 2014, ISSN 0174-4909 , p. T2 ( online [accessed December 12, 2014]).
Individual evidence
- ↑ IBC manufacturer with description [1]
- ↑ http://www.ucon.de/fileadmin/pdf/Bericht_UCON_BAM.pdf "Fire test passed", in gefahrgut-online 03/2011
- ↑ Archived copy ( Memento of the original from March 27, 2014 in the Internet Archive ) Info: The archive link was inserted automatically and has not yet been checked. Please check the original and archive link according to the instructions and then remove this notice.
