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The IBC filling is a process in which products or substances are filled into Intermediate Bulk Containers (IBCs) for storage, transportation, or other intended uses. Different types of IBC filling have been developed to meet various industrial needs.
Open-Top IBC Filling:
The design of an open-top IBC filling provides unrestrained access from above. This feature facilitates fast and uncomplicated filling, cleaning, and maintenance. In various applications where speed and efficiency are paramount, the practical design of this type aids in streamlining processes and reducing downtime. Plastic open-top IBCs are mainly used in this type of IBC filling.
Closed IBC Filling:
This IBC filling provides a secure and sealed environment for filling products inside the container. It helps prevent contamination, spillage, or leaks during transportation and storage. Closed IBCs offer added protection against external factors such as weather conditions, pests, or tampering, ensuring the integrity of the stored contents. Closed IBC filling is commonly used of closed plastic IBCs, steel IBCs, and composite IBCs.
Top loading IBC filling:
In this kind of filling, the material is put into the IBC container from the top using a funnel or a port. Top loading IBC filling is versatile and commonly used in plastic IBCs, steel IBCs, and composite IBCs.
Bottom unloading IBC filling:
This type of filling involves extracting the material from the bottom of the IBC container, usually through a valve or a tap. Bottom unloading IBC filling is convenient for controlled and precise dispensing and is prevalent in chemical or food processing facilities.
Automated IBC filling:
Automated IBC filling systems utilize machines or conveyors to fill products into IBC containers. These systems offer high speed, accuracy, and efficiency in the filling process, reducing labor and improving productivity. Automated IBC filling is commonly used in large-scale industrial settings where high-volume filling is required.
IBC filling with pumps:
Pump-based IBC filling systems involve using pumps to transfer liquids or substances into the IBC container. This method allows for precise control over the filling rate and volume, making it suitable for applications that require accurate measurement and repeatability. IBC filling with pumps can be utilized in various industries, including chemicals, pharmaceuticals, and food and beverage.
The IBC filling machine specification varies depending on the type, model, and brand. Users can expect to find length, width, and height measurements, along with capacity specifications that usually range from 1,000 to 3,000 liters (264 to 793 gallons). The weighing system may have a capacity of 5,000 or 10,000 kilograms with an accuracy of ± 1.0 kg/± 0.01% or better. Its control system usually has an interface with a touchscreen, PLC, and software with different languages.
Temperature control and pressure measuring systems' specifications may vary depending on the fluids being handled. For example, when dealing with food products, pressure specifications may be between -1 and +5 bar, and the temperature may be between -10 °C and +90 °C. The system may also come with a quick-release coupling, valves, and sensors for better performance and handling, and it may provide a report with batch data weighing details.
IBCs must be handled with care. Users should follow the manufacturer's instructions for maintenance and storage. They should also clean the equipment using approved chemicals and filtration systems. The equipment can be partially cleaned by rinsing it with water or entirely cleaned by using steam or cleaning solutions. If using a solution, ensure it is food-grade. If there is any chemical residue, ensure it is removed before using the IBC for food products.
Rarely, an IBC may develop a cleaning issue, so to help avoid this, make sure the liquid being loaded is at least halfway full. Do not use harmful chemicals or stop in the middle of the filling process. Always load the liquid from the bottom rather than from the top to avoid contamination.
Always drain the IBC before it is filled with any type of liquid to avoid over-spill. If any liquid gets on the outside of the IBC, do not wipe it with a cloth as this may cause contamination.
When developing a supply chain for IBCs, consider the IBC filling station. These stations can help reduce the cost of mobilizing IBCs.
When choosing an IBC filling machine for specific requirements, a few key factors must be considered to ensure the optimal fit for the application. The following decision-making criteria will help buyers choose the ideal IBC filling machine for their unique application requirements.
Assess Products's Characteristics
To begin with, buyers need to thoroughly examine the product features they intend to use the IBC filling machine to handle. The buyer's unique product features will determine what type of IBC filing machine they require. Some of the product features to look out for include viscosity, granularity, temperature, pressure sensitivity, corrosiveness, and so on.
Determine Industries Applications
Buyers need to consider the industry they intend to use the IBC filling machine in. Different industries have diverse standards, norms, and requirements. Thus, it is imperative to consider the distinctive filling requirement of each industry. For instance, the chemical industry may require an IBC filling machine with features to handle hazardous materials, while the food industry may prioritize machines that comply with strict hygiene standards.
Contemplate Sizes and Dimensions
Buyers need to consider the IBC container size and dimensions they intend to work with. It's important to choose a filing machine that is compatible with the buyer's IBC containers to ensure smooth operation and avoid the unnecessary risk of straining or damaging the containers.
Volume through Requirement
Buyers need to consider their required volume and throughput. The capacity and speed of the IBC filling machine significantly affect productivity. Buyers need to consider the anticipated volume of filing tasks and select a machine that can easily accommodate the requirement.
Budget Constraints
Budget constraint is another important factor that buyers may need to consider when choosing an IBC filing machine. Buyers need to choose a machine that offers the ideal balance of performance and features at a price point that aligns with the budget.
Filling Accuracy and Precision
Buyers need to prioritize the IBC filling machine's accuracy and precision. This is particularly important for industries where exact measurements directly affect product quality and regulatory compliance.
Flexibility and Scalability
It might also be helpful if buyers considered the IBC filling machine's ability. In most cases, it is ideal to choose a machine that is capable of accommodating different container types and sizes. It might also be useful if the machine has the capacity to cope with future increases in production volume.
Q: How much does a filled IBC tank weigh?
A: The total filled weight of an IBC is approximately 1,000 kg (1 metric tonne) for liquids with a specific gravity of around 1, which is the case for many common liquids and water.
Q: Are IBCs pressure rated?
A: No, IBCs are not pressure-rated containers. They are not manufactured to hold pressure inside the container, and any external pressure can damage them.
Q: Who invented IBC containers?
A: The concept of intermediate bulk containers (IBCs) was first developed in the early 1960s by Karl Klein, a German industrialist and inventor, after which the design spread around the globe.
