BULK BAG (FIBC) SAFETY
Ensuring the safe handling and discharging of bulk bags is crucial to maintaining a safe working environment. At Six Star Bulk Bag, we prioritize safety and quality, providing high-standard FIBCs (Flexible Intermediate Bulk Containers) for various industries. This guide offers detailed instructions and best practices for filling, discharging, storing, and transporting bulk bags. Additionally, it covers essential topics such as food safety, handling safety, UV stabilization, flame resistance, the use of pouches, methods to prevent tampering, and mitigating risks associated with static electricity.
The safe working load (SWL) is the maximum weight a bulk bag can safely hold without risking failure. Exceeding this weight can lead to bag failure, causing injuries or fatalities. Always check your bag’s SWL and ensure you do not exceed it during use. Using woven polypropylene bulk bags correctly as per the instructions provided by both your supplier and the manufacturer is crucial to ensure safety.
What is Safe Working Load (SWL)?
The SWL represents the maximum load limit that can be safely carried by a bulk bag without risking damage or injury. It's vital to ensure that the weight of the material being transported doesn't exceed the load limit of the bag, as this could result in damage to the fabric or seams, and could even lead to injuries. Always check the SWL of a bulk bag before use, and never overload a bag beyond its limit.
5:1 FIBC
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Single Use: Designed for one use/trip with a safety factor ratio (SFR) of 5:1, meaning it can hold five times its rated SWL. Although this is extremely dangerous and should never be done.
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Safety Tip: Never reuse a 5:1 bag. These bags are intended for single use only and should not be repurposed for additional trips or applications.
6:1 FIBC
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Multiple Uses: Suitable for multiple uses with an SFR of 6:1, meaning it can hold six times its rated SWL. Ensure the bag is cleaned, reconditioned, and inspected between uses.
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Safety Tip: Follow FIBCA’s guidelines for reusing bags to ensure safety. This includes thorough cleaning, inspecting for damage, and proper documentation of each use.
Differences Between 5:1 and 6:1 Bulk Bags
The main difference between 5:1 and 6:1 bulk bags lies in their intended use and safety factor ratio. While 5:1 bags are designed for a single use/trip, 6:1 bags are manufactured for multiple uses and can carry heavier loads. It's important to understand these differences to determine which type of bag is right for your application.
Purchasing and Using Refurbished FIBCs
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Inspection and Certification: Refurbished or used FIBCs should come with proper documentation of inspection and certification. Ensure that these bags have been thoroughly inspected for any potential weaknesses or damage.
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Multi-Use Capabilities: Only bags with multi-use capabilities (6:1 SFR) should be purchased. Single-use bags are not suitable for reuse and can pose significant safety risks.
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Safety Factor Ratio: Always ensure that the safety factor ratio (SFR) of the bag is appropriate for your application. Overloading a bag can lead to catastrophic failure.
Reusing Bags Safely
To safely reuse bags, FIBCA suggests the following guidelines be followed:
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Cleaning: Remove all foreign matter from the bag's interior and ensure statically held dust is less than four ounces in total. Replace the liner if applicable.
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Reconditioning: Replace web ties, labels, tickets critical to safe use, and cord locks if necessary.
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Tracking: Maintain a record of origin, product used in the bag, and the number of uses or turns.
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Testing: Randomly select bags for top lift testing. The frequency and quantity should be determined by the manufacturer and/or user based on their specific situation.
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Reasons for Rejecting a Bag: Lift strap damage, contamination, dampness, mold, wood splinters, and smeared or unreadable printing.
Our Multi-Use Bulk Bag Program
At Six Star Bulk Bag, we offer a comprehensive Multi-Use Bulk Bag Program designed to maximize the lifespan and safety of your FIBCs. This program includes:
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Regular Inspection: Each bag is inspected for wear and tear after each use to ensure it meets safety standards.
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Professional Cleaning: Bags are thoroughly cleaned to remove any residues that might compromise the bag’s integrity or contaminate new loads.
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Detailed Documentation: A digital tracking system records the history of each bag, including inspections, repairs, and uses, ensuring full transparency and traceability.
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Quality Repairs: Necessary repairs are conducted using high-quality materials to extend the life of the bags while maintaining safety standards.
By following these guidelines and leveraging our Multi-Use Bulk Bag Program, you can ensure the safe and efficient use of bulk bags in your operations. For more information, check out our Multi-Use Bulk Bag Program.
02 How to Weigh Bulk Bags and Stay Within the Rated Safe Working Load (SWL)
Transporting and storing large quantities of materials in flexible bags (FIBCs) can be inherently dangerous, making safety a top priority at Six Star Bulk Bag. The safe working load (SWL) is one of the most crucial factors to consider when using bulk bags. But how do you determine the SWL of your bag? How can you ensure you're not exceeding this limit?
All About Safe Working Load
The SWL is the maximum weight a bulk bag can safely hold without failing. Exceeding this weight can lead to bag failure, posing severe risks such as injury or death. Knowing your bag’s SWL and adhering to it is vital for safe operations.
At Six Star Bulk Bag, we calculate the SWL for our customers. This ensures that the bags used are appropriate for their specific applications. For more accurate calculations, use our Product Weight Guide and Volume Calculator to identify your product's density and determine the suitable FIBC.
The easiest way to find out your bag’s SWL is to contact your supplier or inquire during the purchasing process.
Weighing Industrial Bulk Bags
Once you have chosen a bag with the appropriate SWL, the next step is ensuring the filled bag's weight remains within this limit. Here are some methods for weighing your filled bags:
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Using Existing Equipment: If your facility has pallet wrappers, you're in luck. Most pallet wrappers come with built-in scales, allowing easy weighing of filled bags. Additionally, specialized filling equipment often can weigh products during filling or after the bag is filled.
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Industrial Scales: If your facility lacks equipment capable of weighing large items like bulk bags, industrial scales designed for pallets are a reliable option. These scales can weigh up to 10,000 pounds and are available at reasonable prices, often under $3,000.
By leveraging existing equipment or investing in industrial scales, you can ensure your FIBCs are within the safe working load, maintaining a safe work environment.
Download Bulk Density List to identify the bulk density of your product. In this list we have included the Density of 999 products.
Contact Us for SWL Calculations
At Six Star Bulk Bag, we assist customers in calculating the SWL to ensure their operations are safe and efficient. Contact us to determine the right SWL for your product and application. Prioritize safety with the right equipment and accurate weight measurements for all your FIBC needs.
04 The 7 Critical Points for Filling and Emptying a Bulk Bag (FIBC)
At Six Star Bulk Bag, safety is our top priority. We integrate rigorous safety practices in all our operations and are committed to educating our customers on maintaining a safe working environment. Recently, FIBCA released a video highlighting the “7 critical points for filling and emptying a bulk bag,” which we believe can significantly enhance the safety of your facility.
The 7 “Critical Points”
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Always Use Every Loop Lift: loops are integral to the structure of FIBCs and are designed to be used together to lift the full rated weight of the bag. Never use fewer than all provided loops as this increases the risk of tearing and dropping the bag.
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Never Gather Loops: Do not gather loops to lift with a single hook unless the bag is specifically designed for this purpose. Using loops incorrectly can be extremely dangerous.
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Keep Loops Vertical: Lift loops should always be lifted vertically, not horizontally. Lifting bags laterally can damage them and create instability, endangering nearby workers.
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Keep Clear of Suspended FIBCs: Never stand underneath or near a suspended FIBC. If the bag becomes dislodged, it can cause severe injury or death.
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Never Exceed the Safe Working Load (SWL) or Rated Capacity: Each bag has a specified SWL, which must not be exceeded under any circumstances. Exceeding the SWL increases the risk of bag failure, leading to serious injury or death.
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Fill the Bag Evenly and Keep it Stable: Ensure the bag is filled evenly to maintain stability. An unevenly filled bag can topple during filling and discharging, posing a danger to workers.
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Close the Bag as Instructed: Properly closing the bag is crucial for safe performance. An improperly closed bag can leak during storage and transport, creating hazardous conditions.
Additional Safety Tips for Filling
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Always Fill in an Appropriate Environment: Ensure the environment is safe and suitable for filling and discharging, particularly when handling flammable or explosive materials. Static electricity can build up, posing severe risks. For these situations, Type C and Type D bulk bags are recommended.
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Always Make Sure the Bag Bottom is Secure before Filling: Verify that the bottom discharge spout is securely closed before filling the bag. Follow the manufacturer’s instructions to ensure proper closing.
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Make Sure Your Handling Equipment is Adequate: Ensure that equipment like forklifts are rated to handle the weight of filled bags and that safety latches are always used.
For a detailed visual guide, please watch the FIBCA video embedded below.
Ensuring safety in your operations not only protects your employees but also enhances the efficiency and reliability of your processes. For more information or if you have any questions, please reach out to our safety experts at Six Star Bulk Bag.
03 Storing Empty & Full Bulk Bags
Storing FIBCs (Flexible Intermediate Bulk Containers) properly is essential to ensure safety and prevent accidents. At Six Star Bulk Bag, we emphasize following safe use guidelines provided by manufacturers, suppliers, and the Flexible Intermediate Bulk Container Association (FIBCA). Neglecting these guidelines can lead to damaged bags, increasing the risk of accidents and injuries. Whether you are storing empty or full bags, adhere to the following best practices.
Storing Empty & Full Bulk Bags
Proper storage of both empty and full FIBCs is crucial. Here are the best practices based on FIBCA's guidelines:
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Safe and Clean Facility: Store bags in a clean environment that shields them from UV rays and moisture to maintain their integrity.
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Protection from Contaminants: Cover bags to protect them from dirt, dust, and moisture.
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Damage-Free Bags: Ensure all bags are free from damage before storing.
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Stable Stacking: Stack bags stably using either the Pyramid or Supported Stacking method:
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Pyramid Stacking: Each bag in the layer above should rest on at least four lower bags, creating a pyramid structure.
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Supported Stacking: Stack bags against two sturdy retaining walls.
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Appropriate Pallets: Use pallets of the correct size. Bags should not overhang unless specifically designed for it.
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Smooth Handling: Raise and lower bags smoothly to prevent damage.
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Manufacturer's Instructions: Follow all recommendations and instructions from the bag’s manufacturer and supplier.
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Regulatory Compliance: Adhere to all regulatory and safety requirements.
Things to Avoid
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Direct Sunlight: Do not store bags in direct sunlight, as UV rays can weaken them over time.
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Inclement Weather: Avoid storing bags in areas exposed to harsh weather conditions.
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Unstable Stacking: Ensure bags are stable before stacking.
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Repairing Under Load: Do not repair a damaged bag without first removing any bags stacked on top of it.
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Improper Pallet Use: Never allow a bag to overhang a pallet unless approved by the manufacturer.
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Unsecured Transport: Do not transport bags unless they are properly secured.
By following these guidelines, you can ensure a safe working environment and prolong the life of your FIBCs. For a detailed guide on safe bulk bag handling, including storage, filling, handling with cranes or hoists, handling with forklift trucks, transportation, and discharging, download FIBCA’s FIBC Safe Handling Guidelines.
If you have any questions or need further assistance, please reach out to our bulk bag experts. We are here to help ensure your safety and the proper use of our products.
Ensuring safe practices when filling and discharging flexible intermediate bulk containers (FIBCs) is crucial to prevent accidents, injuries, and fatalities, especially when dealing with combustible or flammable materials. Follow the guidelines provided by manufacturers, suppliers, and the Flexible Intermediate Bulk Container Association (FIBCA) to maintain safety standards.
Best Practices for Filling and Discharging FIBCs
When filling and discharging bulk bags, ensure that all personnel take necessary safety precautions and are aware of their surroundings. Proper safety gear should be worn at all times. Here are the essential best practices to follow:
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Inspect for Damage: Ensure the bag is free from any damage that could compromise its strength.
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Secure Bottom Discharge: When filling, make sure the bottom discharge spout is properly closed and secure.
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Compatibility: Use a bag that is compatible with the product being packed, especially for dangerous goods and hazardous materials.
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Environmental Suitability: Ensure the bag is appropriate for the filling/discharging environment, addressing any electrostatic concerns in flammable or explosive settings.
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Even Filling: Fill the bag evenly to maintain stability.
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Stability: Keep the filled bag stable at all times.
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Rated Capacity: Use devices with a capacity rated sufficiently to suspend and support the filled bag.
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Vertical Lift Loops: Ensure all lift loops or sleeves are vertical to prevent damage.
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Proper Suspension: Suspend the bag as per the manufacturer’s/supplier’s instructions.
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Smooth Handling: Raise and lower the bag smoothly, ensuring crane hooks/bars or forklift tines are free of sharp edges.
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Close Fill Spout: Properly close the bag’s fill spout after filling.
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Dust Control: Implement measures to control dust around the bag to prevent dust ignition.
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Personnel Safety: Ensure all personnel stay clear of potential hazards and wear appropriate safety gear.
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Follow Instructions: Comply with all handling recommendations and instructions from the supplier.
Key Safety Tips
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Never fill a bag with an incompatible product.
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Do not exceed the safe working load (SWL) of the bag.
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Ensure the bag is suitable for the filling environment.
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Avoid filling a bag to a level that compromises its stability or exceeds height or width limitations.
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Only use devices specifically designed to support the bag.
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Prevent personnel from placing any appendage under a suspended bag.
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Always use an approved safety latch when suspending a bag.
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Consult your supplier/manufacturer before handling a damaged bag.
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Do not lift and suspend a bag using fewer lift loops/sleeves than provided.
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Adhere to all applicable safety requirements.
Comprehensive Safety Guide
For a safe working environment, it is crucial to adhere to these guidelines and best practices. For a more detailed guide on safe bulk bag handling, including:
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Storage of empty bags
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Filling of bags
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Handling with cranes or hoists
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Handling bags with forklifts
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Storage and transportation of filled bags
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Emptying/discharging bags
Download FIBCA’s comprehensive FIBC Safe Handling Guidelines here or contact Six Star Bulk Bag’s experts for any safety-related questions.
When handling Flexible Intermediate Bulk Containers (FIBCs), it is essential to adhere to safe use guidelines set forth by manufacturers, suppliers, and the Flexible Intermediate Bulk Container Association (FIBCA). Improper handling with cranes, hoists, and forklifts can lead to severe injuries or fatalities. Below are crucial guidelines to ensure safe handling of bulk bags.
Best Practices for Handling Bulk Bags with Cranes, Hoists, & Forklifts
Handling bulk bags requires utmost care. Full bags can weigh up to 5,000 lbs., and improper handling can create a hazardous work environment. Follow these best practices for safe handling:
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Inspect for Damage: Ensure the bag is free from damage that could compromise its strength.
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Rated Capacity: Use cranes, hoists, or forklifts that have a sufficiently rated weight capacity to support the filled bag.
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Avoid Sharp Edges: Make sure hooks, bars, or forklift tines used for lifting do not have sharp edges that could damage the bag’s lift loops or sleeves.
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Use Designed Devices: Only use devices specifically designed for handling FIBCs.
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Vertical Lift Loops: Ensure all lift loops/sleeves are vertical to prevent damage.
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Follow Instructions: Lift and suspend the bag as per the manufacturer’s and supplier’s instructions.
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Smooth Handling: Raise and lower the bag smoothly.
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Safety Gear: All personnel should wear proper safety gear and stay clear of potential hazards.
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Forklift Operation: The distance between the forklift tines should be correct for the bag being handled. The forklift operator should keep the bag close to the mast, as low as possible, and tilted back to a proper angle.
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Proper Pallets: Ensure pallets used are the appropriate size and free of sharp objects.
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Clear Visibility: The forklift operator must have a clear line of sight before moving the bag.
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Stop Movement Before Adjustment: The forklift should be stopped before raising or lowering the bag.
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Personnel Clearance: Ensure all personnel are clear before lifting or lowering a bag.
Key Safety Reminders
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Never Handle a Damaged Bag: Do not handle a bag that shows any signs of damage.
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Do Not Exceed Capacity: Never exceed the lifting capacity of the crane, hoist, or forklift.
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Use Appropriate Equipment: Only handle bags with devices specifically designed for that purpose.
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Proper Hook Usage: Do not lift a bag with one hook unless it is designed for that purpose.
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Visibility for Operators: Ensure machinery operators always have a clear line of sight.
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Avoid Standing Under Suspended Bags: Personnel should never stand under a suspended bag.
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Approved Handling Methods: Handle bags only in ways approved by the manufacturer and supplier.
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Proper Lifting Techniques: Always use the provided lift loops or sleeves and keep the bag vertical.
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Avoid Dragging Bags: Never push or drag a bag on the ground.
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Motion Control: Never raise or lower a bag while the forklift is in motion.
Additional Safety Guidelines
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Equipment Ratings: Always ensure equipment is rated for use with FIBCs. If unsure, consult with the equipment dealer or manufacturer.
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Safety Latches: Make sure safety latches and harnesses are used consistently.
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Weight Limits: Never exceed the bag's maximum rated weight.
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Avoid Sharp Edges: Equipment should have rounded edges with a minimum radius of 5mm to prevent tearing.
Forklifts Specifics
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Use All Lift Loops: Never suspend the bulk bag with fewer loops than provided.
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Level Tines: Ensure forklift tines are level to keep lift loops vertical.
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Clear Pallets: If using pallets, ensure they are free of nails and protrusions and are properly sized.
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Proper Positioning: Keep the bag close to the mast and avoid tilting forward.
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Safe Maneuvering: Never move the forklift if the operator’s line of sight is blocked.
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Avoid Ground Contact: Keep the bag clear of the ground and forklift wheels.
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Smooth Movements: Avoid fast starts and stops.
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No Dragging: Never push or drag a bulk bag on the ground.
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Controlled Motion: Stop any forklift motion before raising or lowering the bag.
Cranes and Hoists Specifics
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Use All Lift Loops: Never suspend a bulk bag with fewer loops than provided.
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Single Hook Lifting: Do not gather loops to lift with a single hook unless the bag is designed for it.
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Vertical Lifting: Keep lift loops vertical to avoid damaging lateral forces.
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Clear of Suspended Bags: Never allow personnel under a suspended bag.
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Clear Hazards: Ensure all personnel are clear of potential hazards.
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Electrostatic Concerns: For Type C bags, ensure proper grounding and address all electrostatic concerns before handling.
07 Static Electricity in FIBCs: Mitigating Dangers in Storing Combustible Products
When filling and discharging bulk bags, especially with finely powdered substances, static electricity can accumulate. Proper management of this static buildup is crucial, particularly when handling flammable and combustible materials, as it can be a matter of life and death.
There are four specific types of FIBCs, each with unique features and safe usage guidelines. Understanding these can help you choose the right bag for mitigating the dangers of static electricity.
Type A FIBC Bulk Bags
Type A bags are made of plain-woven polypropylene and other non-conductive fabrics. As products move or rub against the inside surface during filling or discharging, static electricity is generated. Many organic materials and chemicals can form combustible clouds ignitable by electrostatic discharges from Type A bags.
Safe Uses for Type A Bags:
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Transporting non-flammable products.
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When no flammable solvents or gases are present around the bag.
Do Not Use Type A Bags for:
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Transporting flammable products.
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Situations where flammable solvents or gases are present.
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Environments with a flammable atmosphere with a minimum ignition energy ≤1,000mJ.
Type B FIBC Bulk Bags
Type B bags are similar to Type A in that they are made from plain-woven polypropylene fabrics or other non-conductive materials. However, they are made from materials with a low breakdown voltage to prevent highly energetic, dangerous propagating brush discharges (PBD). Despite this, Type B bags are not considered anti-static as they lack a mechanism to dissipate static electricity.
Consequences of Using Type B Bags:
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Electrostatic shocks to operators.
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Attraction of dust and contaminants to the bag's surface.
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Difficulty in fully emptying the bag due to static electricity.
Safe Uses for Type B Bags:
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Transporting dry, flammable powders.
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When no flammable solvents or gases are present.
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Environments with dust with ignition energies less than 3mJ.
Do Not Use Type B Bags for:
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Situations where flammable solvents or gases are present.
Type C FIBC Bulk Bags
Type C bags, also known as conductive or ground-able bags, are made from non-conductive polypropylene fabrics interwoven with conducting threads sewn in a grid pattern. These threads must be electrically interconnected and connected to a designated ground during filling and discharging.
Safe Uses for Type C Bags:
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Transporting flammable powders.
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Situations where flammable vapors, gases, or combustible dusts are present.
Do Not Use Type C Bags for:
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When the ground connection is absent or damaged.
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If resistance from any location of the bag to the designated grounding point is detected.
Type D FIBC Bulk Bags
Type D bags are made from anti-static and static dissipative fabrics designed to prevent sparks, brush discharges, and propagating brush discharges without needing a connection to a designated ground. For instance, Crohmiq™ bags use quasi-conductive yarns that dissipate static electricity into the atmosphere via low-energy corona discharge.
Safe Uses for Type D Bags:
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Transporting flammable powders.
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Situations where flammable vapors, gases, or combustible dusts are present.
Do Not Use Type D Bags for:
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When the surface of the bag is contaminated or coated with conductive material such as grease or flammable substances.
Choosing the Right Bag for Your Application
While Type B bags offer some anti-static properties, only Type C and D bags are safe for storing and transporting flammable and combustible materials or for use when flammable vapors, gases, or combustible dusts are present. Type C bags require proper grounding, while Type D bags eliminate the risk of human error by using special yarns to dissipate static electricity.
For more detailed information on antistatic FIBCs check our "Antistatic FIBCs" page. To determine which type of bag is right for your application, speak with one of our experts by filling out our “Get Quote” contact form
08 The Increased Risks Associated with Type C FIBC Bulk Bags
Flexible Intermediate Bulk Containers (FIBCs) can accumulate significant electrical charges due to static electricity during the handling, filling, or discharge of materials. This buildup poses serious risks to handlers and others nearby, especially in environments involving flammable or combustible materials.
To address these risks, manufacturers have developed Type C and Type D bulk bags, specifically designed to mitigate static buildup dangers. However, Type C bags can still present increased risks due to potential human error.
Understanding Type C FIBC Bulk Bags
Type C FIBC bulk bags are constructed with non-conductive polypropylene fabrics interwoven with conductive threads. These threads form a grid pattern and must be grounded via a cable attached to the bag's sidewall. This grounding is essential to dispel any static electricity accumulated in the bag.
When correctly grounded, Type C bags effectively mitigate static buildup, making them safe for handling and transporting flammable or combustible materials.
Risks of Human Error
The main risk with Type C FIBC bulk bags arises from improper grounding. If the grounding cable is not properly connected, or if grounding is neglected, the bag's anti-static properties become ineffective. This can lead to dangerous static buildup, creating hazardous working conditions and potentially causing serious injuries or even fatalities.
Reducing Risk with Type D FIBC Bulk Bags
To minimize the risk of human error, Type D FIBC bulk bags are recommended. Unlike Type C bags, Type D bags do not require grounding. Instead, they are made from anti-static and static dissipative fabrics that prevent static buildup. These fabrics contain quasi-conductive yarns that dissipate static electricity into the atmosphere through low-energy corona discharge.
Type D bags, such as the CROHMIQ™ brand, eliminate the need for grounding and significantly reduce the human element in managing static electricity risks.
Summary
For those handling static-sensitive materials, the choice between Type C and Type D FIBC bulk bags is crucial. While Type C bags are effective when grounded properly, Type D bags offer a safer, more reliable alternative by removing the potential for grounding errors. Understanding the differences and appropriate uses of these bags can enhance safety and efficiency in your operations.
09 How to calculate the Capacity of a Bulk Bag?
A bulk bag’s capacity indicates how much material it can hold. Whether you’re using your bulk bags to transport sand, gravel, animal feed, or another substance, the capacity tells you what volume of material can fit into the bag. Bulk bag capacity is often given in cubic meters — for example, one cubic meter for a standard-sized bag — though different companies may use cubic feet. It’s easy to convert between the two using a conversion table or an online calculator.
So, how much volume does a bulk bag hold? Volumetric capacity depends on the bag. The dimensions of a bulk bag are helpful determiners. In general, bulk bags follow the basic formula for volume: volume equals length times width times height. Under this formula, a 35-inch by 35-inch by 35-inch bag can hold about 42,875 cubic inches, or 25 cubic feet, of material. Bags with larger dimensions offer increased capacity.
However, bulk bag manufacturers also typically take the effects of bulging into their capacity calculations. Bulging occurs when the sides of a bulk bag bow outward under the pressure of the product filling them. Bulging is natural, safe, and expected — the bag's material is sturdy and flexible.
Because bulging allows the bag to expand beyond its initial dimensions, it also allows for a slightly greater capacity than you would expect from the formula given above. So, manufacturers often add a little extra to the capacity as determined by the product of the length, width, and height of the bag.
Choosing Bulk Bags for Capacity
When customizing bulk bags, it's crucial to consider dimensions that add capacity while maintaining storage and transport convenience. Generally, increasing the height of the bag is the most efficient way to add capacity without affecting the bag's compatibility with standard pallets, which typically measure 35 by 35 inches. Adjusting width or length might make the bags too large for pallets, even though they might fit on common carriers.
Volumetric Capacity vs. Weight Limit
It's important to distinguish between volumetric capacity, which refers to the volume of material a bag can hold, and the weight limit, the maximum weight the bag can safely support. Different FIBCs have varying maximum load weights and dimension limits. For safe capacity calculations, consulting with a professional bulk bag company like Six Star Bulk Bag is recommended.
Factors Affecting Bulk Bag Capacity
Several factors influence a bulk bag's capacity:
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Inlet Type: The type of filling inlet affects capacity. Open tops offer more flexibility for larger items, while spout tops may restrict capacity.
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Rounding: Bulk bags tend to round out as they fill, potentially squeezing the product and reducing capacity. Baffled bulk bags, with sewn-in panels, help resist rounding and preserve capacity.
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Loops: The lifting loops determine the feasible size of the bag, as additional clearance is needed for the loops' height.
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Density of Material: The material's density significantly impacts the bag's capacity. Higher-density materials result in lower capacity due to weight limitations.
Low-Density Materials vs. High-Density Materials
The type of material transported affects the bag's weight and capacity:
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Low-Density Materials: These materials are lighter, allowing bags to be filled to full volumetric capacity without exceeding the safe working load (SWL).
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High-Density Materials: These materials are heavier. A bag filled with high-density materials might exceed its SWL before reaching full volumetric capacity, requiring underloading to maintain safety.
Ensuring Safe Working Load (SWL)
To ensure that the product you’re packing does not exceed the safe working load of the FIBC, you need to know the bulk density of the product as well as the cubic foot capacity of the FIBC. Follow these steps:
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Download our Bulk Density List and Cubic Foot Capacity Calculator: Click on the red buttons on this page to download these tools.
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Identify the Bulk Density: Use the downloadable Bulk Density list to find the bulk density of your product.
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Calculate Cubic Foot Capacity: Enter the desired dimensions of the baffled or non-baffled FIBC in the calculator to determine its cubic foot capacity.
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Calculate the Weight: Multiply the bulk density by the cubic foot capacity to find out how much weight will be in the bag.
Example Calculation
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Check Bulk Density List: Suppose you're packing Barley Meal, and the list states it’s 28 lbs. per cubic foot.
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Use Calculator: You want a non-baffled bag with dimensions 35” x 35” x 40”. Entering these figures in the calculator shows a cubic foot capacity of 34.1 cubic feet.
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Calculate Weight: Barley Meal Bulk Density of 28 lbs. per cubic foot multiplied by 34.1 cubic feet equals 954.82 lbs. in the FIBC.
Result
Six Star Bulk Bag offers stock bags of this size with safe working loads of 2,200 lbs. and 3,000 lbs. Alternatively, we can design a custom bag with a safe working load of 1,000 lbs., reducing the weight of the fabric and leading to cost savings compared to stock bag options.
For a comprehensive guide on safe bulk bag handling guidelines, including storage, filling, handling with cranes or hoists, handling with forklifts, transportation, and emptying, consult with Six Star Bulk Bag experts.
10 Food Safety
Food Grade Bulk Bags - Rules and Regulations Impacting Your Operation
Navigating the complex web of regulations for food-grade bulk bags can be challenging. There are many regulatory bodies providing guidelines on food packaging, including AIB (American Institute of Baking), FDA (Food and Drug Administration), HACCP (Hazard Analysis Critical Control Point), ISO 22000 (International Organization for Standardization), BRC (British Retail Consortium), and GFSI (Global Food Safety Initiative). Let's break down these regulations and focus on what matters most for your operation.
Why So Many Regulatory Bodies?
Despite the numerous regulatory bodies, their common goal is to ensure the safety of food producers, processors, and consumers. The CDC (Centers for Disease Control) estimates that annually, one in six Americans contracts a foodborne illness, resulting in approximately 3,000 deaths. Regulation is essential for protecting consumers and companies in the food supply chain, though there is a need for more uniform standards.
Ensuring Your Bulk Packaging Meets Standards
In the food supply chain, stringent standards are necessary for food grade materials as many food products, such as grains, legumes, flour, salt, and sugar, are transported in bulk bags. The global market is increasingly adopting GFSI (Global Food Safety Initiative) standardization, governed by major food industry players like Cargill, McDonald’s, Wal-Mart, and Nestle. GFSI aims to:
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Reduce food safety risks by ensuring effective food safety management systems.
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Manage costs by eliminating redundancy and improving efficiency.
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Develop food safety competencies globally.
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Provide a platform for collaboration and knowledge exchange.
Moving towards GFSI standardization helps streamline compliance with food safety practices and regulations, providing a unified voice for the food industry.
Continuous Improvement in Food Safety
Food safety encompasses material selection, manufacturing environments, packaging, storage, and transportation. It requires continuous analysis and improvement. Implementing company policies that prioritize food safety and continuous improvement is crucial for maintaining a safe food environment.
What Makes a Food-Grade Bulk Bag Different?
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Materials Used: Food-grade bulk bags are made from 100% virgin polypropylene resin, ensuring no recycled materials that could contaminate food.
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Manufacturing Facilities: These bags are produced in clean rooms within BRC-certified facilities that meet the highest standards of hygiene and safety.
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Inspection and Tracking: Food-grade bulk bags undergo thorough inspections and batch testing, with each batch tracked from manufacturing to end use.
Refer to the Standard FIBC vs. Food Grade FIBC Comparison Chart on our Food Grade Bulk Bag page.
Finding the Right Food Grade Bulk Bag Supplier
When selecting a bulk bag supplier, consider the following:
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Avoid False Claims: Suppliers should not claim FDA approval for bulk bags. Look for suppliers adhering to recognized standards like those set by BRC and GFSI.
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Verify Material Quality: Ensure bags are made from 100% virgin polypropylene resin.
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Transparency: A reputable supplier should provide information about their manufacturing processes and allow facility tours.
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Industry Experience: Choose suppliers with proven experience in the food industry.
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Third-Party Certification: Ensure the supplier's facilities meet third-party certifications like BRC for the highest quality standards.
Choosing Bulk Bags for Capacity
When customizing bulk bags, consider dimensions that add capacity while maintaining storage and transport convenience. Increasing the height of the bag is often the most efficient way to add capacity without affecting pallet compatibility.
Volumetric Capacity vs. Weight Limit
Volumetric capacity refers to the volume a bag can hold, while the weight limit is the maximum weight the bag can safely support. Different FIBCs have varying maximum load weights and dimension limits. For safe capacity calculations, consulting with a professional bulk bag company like Six Star Bulk Bag is recommended.
Ensuring Safe Working Load (SWL)
To ensure that the product you’re packing does not exceed the safe working load of the FIBC, you need to know the bulk density of the product as well as the cubic foot capacity of the FIBC. Follow these steps:
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Download our Bulk Density Guide and Cubic Foot Capacity Calculator: Click on the red buttons on this page to download these tools.
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Identify the Bulk Density: Use the downloadable Bulk Density list to find the bulk density of your product.
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Calculate Cubic Foot Capacity: Enter the desired dimensions of the baffled or non-baffled FIBC in the calculator to determine its cubic foot capacity.
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Calculate the Weight: Multiply the bulk density by the cubic foot capacity to find out how much weight will be in the bag.
Example Calculation
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Check Bulk Density List: Suppose you're packing Barley Meal, and the list states it’s 28 lbs. per cubic foot.
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Use Calculator: You want a non-baffled bag with dimensions 35” x 35” x 40”. Entering these figures in the calculator shows a cubic foot capacity of 34.1 cubic feet.
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Calculate Weight: Barley Meal Bulk Density of 28 lbs. per cubic foot multiplied by 34.1 cubic feet equals 954.82 lbs. in the FIBC.
Result
Six Star Bulk Bag offers stock bags of this size with safe working loads of 2,200 lbs. and 3,000 lbs. Alternatively, we can design a custom bag with a safe working load of 1,000 lbs., reducing the weight of the fabric and leading to cost savings compared to stock bag options.
11 Feed Grade vs. Food Grade: What’s the Difference?
The FIBC (Flexible Intermediate Bulk Container) industry is filled with acronyms, terms, and jargon that can make it challenging to understand the available products and their uses. One common source of confusion is the distinction between "Feed Grade" and "Food Grade" bulk bags. Many people mistakenly assume these terms are interchangeable, but they are quite different. Understanding these differences is essential to ensure you source the proper bulk bags for your specific needs.
Defining the Term "Feed Grade"
"Feed grade" refers to products designed to hold materials intended for animal consumption, including pets, farm livestock, and zoo animals. Feed-grade materials are not certified as safe for human consumption. Additionally, facilities producing feed-grade products are not held to the same rigorous standards as those that produce products for human consumption. Feed-grade bags may be manufactured with recycled resins or resins that are not certified as safe for humans.
In summary, feed-grade FIBCs are intended for products destined for animal consumption. These applications do not require bags certified as safe for human consumption.
Defining the Term "Food Grade"
"Food grade" refers to products certified as safe for human consumption, such as nuts, spices, rice, supplements, sugar, and flour. Products considered food grade are typically manufactured in facilities certified by recognized authorities like the British Retail Consortium (BRC) or the Food and Drug Administration (FDA).
Food grade FIBCs are manufactured with virgin resin in designated clean room facilities. These products allow for up to 100ppm (parts per million) of mold and other potential contaminants while still meeting specifications defined by organizations like the BRC. These levels are deemed "Food Safe" and are not harmful to consumers.
Food-grade bulk bags may also be certified by various food safety standards, including the American Institute of Baking (AIB) and Safe Quality Foods (SQF) standards.
Why Is This Important When Sourcing FIBCs?
The distinction between feed grade and food grade is crucial when choosing bags. For feed-grade applications, which involve products destined for animal consumption, standard FIBCs are often the best and most affordable option.
For food-grade applications, which involve products intended for human consumption, certified food-grade bags are required. Ensuring you use the correct type of bag is vital for maintaining safety and compliance with relevant standards.
12 The Importance of UV Stabilization for Bulk Bag Safety
Understanding UV Stabilization in FIBC Bags UV stabilization involves incorporating additives into the bag material to prevent or minimize the damaging effects of UV radiation. This is crucial for maintaining the strength and durability of FIBCs, as UV exposure can cause discoloration, brittleness, and a significant loss of strength in the bag material. Therefore, selecting UV-stabilized FIBC bags is essential for outdoor applications to ensure they withstand prolonged exposure to sunlight without degrading.
Methods of UV Stabilization Several methods are used to achieve UV stabilization in FIBC bags:
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Addition of UV Stabilizers: These chemical additives are mixed with the polypropylene during manufacturing to absorb and dissipate UV rays as low-level heat.
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UV-Resistant Coatings: Applying a protective coating to the bag material helps shield it from UV radiation.
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Lamination with UV-Resistant Films: Laminating the bags with UV-resistant films provides an extra layer of protection.
Each method has its advantages and disadvantages concerning cost, effectiveness, and impact on the bag's properties. When choosing a UV stabilization method, it’s important to consider the type of material, intended use of the bag, and environmental factors such as climate and sunlight exposure.
Compliance and Standards for UV Stabilization
International standards, such as ISO 21898 and ASTM D 6978, specify requirements for UV stabilization of FIBC bags. Compliance with these standards involves rigorous testing and certification to ensure that the bags maintain their strength and durability even after prolonged UV exposure. Choosing FIBC bags that meet these standards is vital for guaranteeing safety and reliability in outdoor applications.
Why This Matters
UV stabilization is crucial for the safety and functionality of bulk bags. Without it, exposure to sunlight would significantly degrade the material, making the bags unsafe for use. Polymer stabilizers in the bags help absorb UV rays and dissipate them as heat, but they do break down over time. It's essential to consult with suppliers to understand your bag’s UV rating, which is typically expressed in hours of exposure. For instance, Six Star Bulk Bag adheres to the ISO 21898 Standard, limiting UV exposure to 200 hours, although this can be adjusted for custom orders.
The intensity of sunlight varies by location, affecting how long a bag can be exposed before it starts to degrade. For this reason, storing bags outdoors is generally not recommended. However, if outdoor storage is unavoidable, it's crucial to seek additional guidance from your supplier.
Conclusion
UV stabilization is a critical factor in maintaining the safety and durability of FIBC bags, especially for outdoor use. It prevents material degradation, ensuring that the bags remain strong and reliable under prolonged sunlight exposure. When selecting UV-stabilized FIBC bags, consider the type of material, intended use, and environmental factors, and ensure they comply with international UV stabilization standards.
13 How to Know When a Bulk Bag Has Been Tampered With
Introduction Transporting sensitive materials, such as expensive raw materials or government-regulated substances, is a common task for many bulk bag users. Often, these materials are entrusted to third-party shipping companies. Ensuring that these materials have not been tampered with during transit and arrive at their destination in their original condition is crucial. Recent security innovations within the bulk bag industry address these concerns, providing enhanced security features to detect tampering.
Tamper Evident FIBCs Tamper Evident bags are the latest innovation in the bulk bag industry, designed to make tampering and damage evident upon visual inspection. These bags offer enhanced security for organizations shipping sensitive or critical materials, as well as those with a history of tampering or damage by third-party shippers. Key security features of Tamper Evident bulk bags include:
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Specialized Patterning: These bags are constructed with specific patterning of woven polypropylene, designed to match across various sections of the bag. Deviations from the pattern may indicate tampering or damage.
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Continuous Stitching: FIBCs are created with a continuous stitching pattern on all seams. Breaks in this pattern are visual evidence of tampering or damage.
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Security Eyelets: The filling and discharge spouts of Tamper Evident FIBCs include security eyelets, which can be secured with cable ties to prevent unauthorized access.
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Double-Walled Spouts: These spouts allow the bag to be sealed securely. Any tampering or breakage of this seal can be easily identified by the end-user.
These features collectively provide optimal security and confidence for vendors, end-users, and shipping companies, making it easy to identify tampering or damage during shipping or storage.
Explaining Tamper-Evident FIBC Containers Tamper Evident Bags are designed to ensure the integrity of sensitive materials during storage and transportation. These bags are particularly useful in industries such as pharmaceuticals and law enforcement, where the safety and integrity of contents are paramount. Here are some key features and benefits of tamper-evident bags:
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Specialized Patterning: Designed to match across sections, any pattern deviations signal tampering.
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Continuous Stitching: Seamless stitching patterns that, when broken, indicate tampering or damage.
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Security Eyelets: Enhance security by allowing the spouts to be sealed with cable ties.
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Double-Walled Spouts: Secure spouts prevent unauthorized access, with breakages easily identifiable.
These features ensure that tamper-evident bags provide security and confidence for sensitive material shipments.
Applications of Tamper-Evident Bags
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Forensic Industry:
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Preservation of Evidence Integrity: Tamper-proof bags ensure evidence remains untampered.
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Chain of Custody Management: Features like tamper-evident seals and serial numbers help maintain a documented chain of custody.
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Legal Admissibility: Secure evidence handling improves the reliability of evidence in court.
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Protection against Contamination: Bags create a barrier against contaminants, preserving evidence quality.
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Compliance with Professional Standards: Adherence to strict protocols for evidence handling.
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Pharmaceutical Industry:
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Drug Safety: Prevents tampering with medications.
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Brand Protection: Helps combat counterfeit drugs.
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Regulatory Compliance: Meets stringent packaging requirements.
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Improved Customer Confidence: Ensures the safety of medications, increasing consumer trust.
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Efficient Logistics and Distribution: Durable bags reduce damage during transport.
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Considerations for Purchasing Tamper-Evident Bags
When selecting tamper-evident bags, consider the following factors to ensure their effectiveness:
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Tamper-Evident Characteristics: Look for features that clearly indicate if the bag has been opened or tampered with.
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Material Quality: Choose bags made from strong, tear-resistant materials.
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Security Seals: Opt for potent seals like adhesive seals, security tapes, or numbered seals.
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Chain of Custody Documentation: Some bags include surfaces for recording handling details.
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Size and Capacity: Select appropriate sizes and capacities for the items being stored or transported.
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Compliance with Standards: Ensure bags meet relevant industry standards and regulations.
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Supplier Reputation: Choose a reputable supplier with a solid track record and excellent customer service.
For high-quality tamper-evident bags tailored to your needs, consider contacting a reputable manufacturer like Six Star Bulk Bag. They offer customized solutions and prioritize customer satisfaction with responsive service and support.
By understanding and utilizing tamper-evident FIBCs, you can significantly enhance the security and integrity of your sensitive material shipments, ensuring they remain safe and untampered from production to delivery.
