Intermediate Bulk Containers (IBCs) are widely used across industries including chemical, pharmaceutical, food and drink, and oil and gas for the storage and transportation of liquids. However, safely and efficiently filling an IBC requires more consideration than simply transferring product from one container to another.

The media being handled, required flow rate, filling frequency, potential for foaming or splashing, vapour control and operator safety can all influence the type of IBC filling equipment required.

Depending on the application, a relatively simple filling arrangement may be suitable. In other operations, a more engineered solution may be required to provide greater control over the filling process.

Understanding these requirements is the first step towards selecting the right IBC filling equipment for your application.

What Should You Consider When Filling an IBC?

No two filling applications are exactly the same. Before selecting equipment, it is important to understand both the characteristics of the product being transferred and how the IBC filling operation will take place.

Some of the key considerations include:

• Media being transferred – The chemical properties of the liquid will influence the materials, seals and equipment suitable for the application.
• Required flow rate – Higher throughput requirements may require larger equipment and a filling arrangement capable of handling increased flow rates.
• Operating pressure and temperature – Equipment must be specified to suit the conditions of the transfer process.
• Filling frequency – An occasional filling operation may have very different requirements to a production facility filling multiple IBCs throughout the day.
• Foaming and splashing – Certain liquids can foam or splash considerably during filling, particularly when discharged from above the liquid level.
• Vapours – Depending on the media, vapour recovery or a more controlled filling arrangement may be required.
• Hazardous areas – Equipment used within a hazardous area must be designed and specified appropriately for the operating environment.

Considering these factors at the beginning of a project helps determine whether an Engineered Delivery Nozzle, Filling & Emptying Head or Top Loading Arm provides the most appropriate solution.

Controlling Foaming and Splashing During IBC Filling

The way that liquid enters an IBC can have a significant effect on the filling process.

When certain products are discharged directly onto the surface of the liquid, they can generate excessive foam. This can slow the filling process, make it more difficult to judge the fill level and potentially increase the risk of product escaping from the container.

Splashing can create similar problems, particularly when hazardous, corrosive or high-value liquids are being handled.

One solution is bottom filling, where an extended lance or drop pipe allows the product to be introduced closer to the bottom of the IBC. Once the end of the filling pipe becomes submerged, the product can continue to enter below the liquid surface, helping to reduce turbulence, splashing and foam generation. Whether bottom filling is necessary will depend on the properties of the media and the requirements of the application.

Engineered Delivery Nozzles for IBC Filling

For applications where the operator needs a straightforward and controlled method of dispensing product into an IBC, an Engineered Delivery Nozzle can provide an effective solution.

Available in manual and automatic configurations, these nozzles can be used for filling IBCs as well as drums, casks and other containers.

Their relatively compact design makes them particularly useful where an operator needs direct control over the filling process.

Depending on the application, Engineered Delivery Nozzles can also be configured with additional features such as vapour recovery, swivel joints and dust caps.

The correct nozzle configuration will depend on factors including the media, required flow rate, operating conditions and the connection at the filling point.

Filling & Emptying Heads for IBC Applications

Where greater control over the filling process is required, a Filling & Emptying Head can incorporate several functions into one engineered assembly.

Although frequently associated with drums, Filling & Emptying Heads can also be configured for IBC filling applications.

One of their main advantages is the ability to tailor the assembly around the specific process. Depending on the application, options can include:

• Extended filling lances
• Vapour recovery
• Nitrogen purging
• Level or signal switches
• Steam heating
• IBC adaptors
• Quick connect and disconnect couplings

Filling & Emptying Heads can be manufactured in a range of materials, including Stainless Steel, Hastelloy and PTFE-lined configurations, helping accommodate different chemical compatibility requirements. Various connection options are also available, including threaded, flanged and Tri Clamp connections. This flexibility makes Filling & Emptying Heads particularly useful where the filling operation involves more than simply delivering liquid into the container.

For example, an application handling a volatile or sensitive product may require vapour management or nitrogen purging alongside the product filling line. Combining these requirements into a purpose designed Filling & Emptying Head can provide a more controlled filling arrangement.

Using Top Loading Arms for IBC Filling

For repetitive filling operations or applications requiring greater reach and movement, a Top Loading Arm can provide a more permanent engineered solution.

Top Loading Arms are commonly associated with the loading of road tankers and rail cars, but many designs can also be adapted for filling smaller containers such as IBCs.

Rather than relying on the operator to support and manoeuvre a hose during filling, the articulated structure of a Loading Arm allows the filling point to be positioned where required while supporting the weight of the transfer pipework.

This can be particularly beneficial in facilities where IBCs are regularly moved into a designated filling position.

Depending on the application, a Loading Arm can be engineered around factors such as:

• Required working envelope and reach
• IBC filling position
• Product flow rate
• Pipe size
• Materials of construction
• Operating pressure and temperature
• Loading height
• Filling lance or drop pipe requirements
• Movement and operator handling

Long range designs can also provide additional flexibility where the filling arm needs to reach multiple positions within a defined operating area.

Which IBC Filling Solution Is Right for Your Application?

There is no single piece of equipment that is right for every IBC filling operation.

An Engineered Delivery Nozzle may provide an effective solution where relatively straightforward, operator-controlled filling is required.

A Filling & Emptying Head may be more appropriate when additional process requirements such as bottom filling, vapour recovery, nitrogen purging or level detection need to be incorporated.

For frequent filling operations, or where greater reach, support and positioning are required, a Top Loading Arm may provide a more comprehensive solution.

The decision should therefore be based on the complete filling process rather than simply the size of the IBC.

Specifying IBC Filling Equipment

Providing detailed application information from the beginning can make it significantly easier to identify and engineer the correct filling equipment.

Alongside the type and size of IBC, useful information includes the full name of the media being transferred, required flow rate, operating pressure, operating temperature, connection details and required materials. It is also important to identify whether the product foams, whether bottom filling is required and whether vapour recovery, nitrogen purging or other process features are necessary.

The physical layout of the filling area should also be considered, particularly when specifying a Loading Arm. Understanding where the IBC will be positioned and the required reach and movement allows the equipment to be designed around the available working area.

Finding the Right IBC Filling Equipment

The right IBC filling arrangement should make the transfer process safer, easier to control and better suited to the characteristics of the product being handled.

From individual Engineered Delivery Nozzles and Filling & Emptying Heads through to complete Top Loading Arm arrangements, there are several ways to approach IBC filling depending on the requirements of the operation.

EWFM can help assess your application and recommend equipment based on the media, flow rate, container, operating conditions and filling process.

If you are looking to improve an existing IBC filling operation or specify equipment for a new installation, contact the EWFM sales team to discuss your requirements.