PRESENTATION BY: TANIN GUVEN and DAVID LODGE JANUARY 2012
This presentation is prepared for providing information about ATEA Packaging LTD., Inter-Link Packaging Solution’s ISO FIBC manufacturing partner, and an overview of Flexible Intermediate Bulk Containers (FIBCs) at consumer level.
COMPANY FACTS • • • • • • • • • • •
Production plant established in 1975 36 years of experience in PP sacks 15 years of experience in FIBCs ISO certified production since 2003 (ISO9001:2008) 4.5 million pcs/annum FIBC manufacturing capacity State of the art technology used in all production processes (Starlinger Looms, SML Lenzing Extrusion Coating Lines) Experienced staff in FIBC design and conversion Trustworthy products manufactured under strict quality control Each FIBC is quality controlled Proven quality and reliability in the global market Wide range of FIBC models (Upanel, Cross Corner Circular, Baffled, One/Two Loops, Slingbag) Products certified by well known international laboratories
ATEA Packaging Ltd. PHOTOS FROM THE PRODUCTION
ATEA Packaging Ltd.
What You Should Know About FIBCs? To support your decision as an FIBC user, ATEA Packaging has compiled the following information on bulkbag terminology, construction, strength, and characteristics. Polypropylene (PP) PP is a long chain synthetic olefin polymer. It is a thermoplastic material, meaning it can be repeatedly heated to its softening point, shaped, worked, or drawn in the case of fibers, then cooled to preserve its shape. The drawn fibers or yarns are used to construct the finished PP woven fabric. PP is widely used in technical fabric weaving because of its relatively low cost, and because it can easily be formed into a variety of fiber and yarn sizes. ATEA Packaging Ltd.
Bulk Bag Material ATEA bulk bags are made from extruded sheets of polypropylene film, which are cut into thin strips and wound onto bobbins.
These strips are referred to as tapes. The tapes may vary in thickness and width, depending on the application. The tapes are then woven into material that will be used to construct the various parts of the intermediate bulk containers (FIBCs). Because the polypropylene material used to make bulk bags is woven, the terms used to describe the material are identical to those used in the textile industry.
Material Strength Suppliers and consumers of PP bags usually describe the material by its areal density. Areal Density is the dry fabric weight. The most common unit of measure is grams per square meter. ATEA bulk bags are available in any weight according to the Safe Working Load (SWL), filled product properties, and handling and transportation means. To describe the strength of the tape, the industry uses the term Denier. Denier is a numbering system for yarn and filament in which yarn number is equal to weight in grams of 9000 meters of yarn. The Denier rating is directly correlated to the thickness of the tape.
The weave density of the material also affects the bag strength. Vertical tapes are known as the warp and horizontal tapes as the weft. The weave density refers to the number of warp tapes and weft tapes per square inch of fabric. For example, a 14 x 14 fabric has 14 vertical tapes (warp) and 14 horizontal tapes (weft) per square inch. Material can be strengthened by making either the warp or weft tapes thicker, or by increasing the weave density. Tensile strength another term that is used to describe the strength of the material used to construct the intermediate bulk containers. Tensile strength is measured by pulling a 5 cm wide strip of cloth until it breaks.
History of Bulk bags Flexible Intermediate Bulk Containers (FIBCs) have been used for packaging purposes since the1940's. FIBC forerunners to contemporary bulk bags were constructed of PVC rubber, and were mainly used in the rubber industry to move carbon black in two ton loads. In the 1960s, with the advent of polypropylene and specialized weaving technology, oil and chemical companies began to use bulk bags for handling granular or coarse grained powdered base chemicals and fertilizers. The use of bulk bags spread across industries in the late 1970s. Since then bulk bags usage has grown dramatically worldwide.
FIBC shipments have increased 10% - 15% per year over the past decade. Today, bulk bags are used extensively throughout the world for food, chemical, pharmaceutical, and agricultural packaging purposes. With the increased availability of specifically designed filling and discharging machines, the use of bulk bags has increased rapidly over the years.
The popularity and use of bulk bags will continue to grow as handling becomes increasingly easier and cost savings are even more readily identifiable over other types of packaging.
FIBC-categories for non-dangerous goods The FIBCs for non-dangerous goods are divided into three categories according to their use: Single-trip FIBCs (safety factor SF = 5:1) Such bags are made for example of polyolefin fabrics, coated or uncoated, with or without an inner liner. These bags are designed and intended to be used for one filling only. An FIBC of this category cannot be reused. Neither replacement of an inner liner, nor repair of the FIBC, is relevant to this category. Reuse of FIBCs certified and marked as single trip FIBCs is not in conformity with the standards. Standard duty reusable FIBCs (safety factor SF = 6:1) Such bags are made for example of polyolefin fabric, coated or uncoated, with or without an inner liner, and used mainly in closed loop between filler and discharge of the FIBC.
Standard duty reusable FIBCs (safety factor SF = 6:1) (continued) These bags are designed and intended to be used for a limited number of fillings and discharges. An FIBC of this category cannot be reused if damaged, i.e., is not repairable. (The replacement of a removable inner liner is not considered a repair.) FIBCs certified and marked as “Standard Duty Reusable FIBCs� in conformity with the standards shall be reused only with the same type of contents as in the first use. Reuse of FIBCs with contents differing from those of the first use is not in accordance with the standards.
Heavy duty reusable FIBCs (safety factor SF = 8:1) Such bags are made, for example, of polymetric fabric continuously coated on one or both sides with plastics material, e.g., PVC. These bags are designed and intended to be used for a multitude of fillings and discharges, and are both factory and field repairable in such a way that the tensile strength across a repair is at least as great as that of the original. Repairs should be carried out so that the repaired FIBC is capable of meeting the requirements of the new FIBCs as marked on the label. Before undertaking any repairs, the manufacturer or supplier should always be consulted. Factors which should be taken into account in deciding whether the FIBC is field repairable, factory repairable, or not repairable include the materials of construction, the type and area of damage, the age of the FIBC, the conditions to which the FIBC has been subjected during service, and the location of the damage.
TYPES OF FIBCS There are several classifications for FIBCs: a. According to their body construction 1. U-Body + 2 side panels 2. Circular Body + base 3. 4 sides + base b. According to their electrical properties 1. Type A 2. Tybe B (Antistatic FIBC BDV<6kV) 3. Type C (Conductive FIBC) 4. Type D (Dissipative FIBC) c. According to their manufacturing process 1. Standard grade 2. Food grade 3. Pharma grade
TYPES OF FIBCS d. 1. 2. 3.
According to their loop style Corner loops Cross corner loops Stevedore loops
e. 1. 2. 3.
According to the number of loops 1 loop FIBcs 2 loops FIBCs 4 loops FIBCs
f. According to their shape after filling 1. Round bags 2. Formstable bags (Baffle and Gambo FIBCs) g. 1. 2. 3.
According to the fabric layers Coated fabric FIBCs Uncoated fabric FIBCs Lined FIBCs
Advantages of the Formstable (Baffle) FIBCs 1. Optimal payload 2. Improved stability 3. Efficient use of storage space 4. Form fastness 5. Customer-friendly packaging 6. Environmentally-friendly packaging The Baffle FIBC allows you to transport many more products than a conventional FIBC, ensuring higher economy during loading, transportation, discharging, and storage. When filled, the Baffle FIBC maintains its rectangular or square shape. The regular FIBC becomes cylindrical in shape after filling. For this reason, the Baffle Bag is able to utilize optimum container space. It is possible to transport and stock 16-23% more product with a BAFFLE FIBC when compared with a standard FIBC. Furthermore these FIBC's are produced using very accurate technical procedures that make them totally sift proof, even for very fine powders. Specially produced sandwich fabric provides extra stability and protection to the bag.
Electrical Properties of FIBCs FIBCs are widely used for the storage, transportation and handling of powdered, flaked, or granular material. Untreated polypropylene is a good electrical insulator, as is often the case with products placed in FIBC's. There is a high possibility for the generation of electrostatic charge during filling and emptying operations, and, in unprotected FIBC's, high levels of charge can quickly build up. In such cases electrostatic discharges are inevitable and can be a severe problem when FIBC's are used in flammable environments. A flammable environment can be generated when handling fine powders that create dust clouds, or thin layers of powder, both of which can be ignited by electrostatic discharges. A flammable environment can also be generated when using gases or volatile solvents. In these industrial situations there is clearly a need to eliminate incendiary electrostatic discharges.
Types of FIBCs Depending on the application 4 categories of FIBCs are available:
Type A - Constructed from non-treated insulating fabric - No requirements are specified for Type A FIBCs - They are not intended for use in potentially explosive atmospheres
Type B - Constructed from insulating fabric but has a breakdown voltage less than 6kV - This provision prevents the risk of energetic propagating brush discharges, which can ignite dust-air mixture - Type B bags may be used in the presence of combustible dusts with MIE of greater than 3 mJ, but in the absence of flammable vapors or gases
Type C (Conductive FIBC) • Constructed from fabrics having interwoven conductive threads • Resistance from any location on FIBC to ground < 108 Ohm. • Must be electrically grounded during filling and emptying • May be used where combustible dusts and flammable atmosphere with MIE of 3 mJ or less are present • No propagating brush discharge, no brush discharges, and no spark discharges are to be expected if properly grounded
Type D (Dissipative FIBC) • Constructed from antistatic fabric that includes static dissipative, antistatic threads • Surface resistance over complete bag surface between 106 and 1010 Ohm • This specific discharge by antistatic threads is called the Corona-effect; grounding is not necessary • May be used where combustible dusts and flammable atmosphere with MIE of 3 mJ or less are present • TypeD bags can be used in Zone 1 • (flammable atmosphere with a minimum ignition energy of 0.15 mJ) • The minimum distance to conductive, non-grounded objects (also persons) has to be 1 meter (charging by induction is possible)
Where to use ? Which type of FIBC to use? Here are some FIBC selection recommendations according to the Minimum Ignition Energy (MIE) of your product/s. MIE>10J Type A, Type B, Type C, Type D 10J>MIE>3mJ Type B, Type C, Type D MIE<3mJ Type C, Type D Dust and flammable solvents Type C, Type D WARNING ! - Type C (Conductive FIBCs) must always be grounded when filled and discharged - Type D (Dissipative FIBCs) must always be used in a grounded environment including staff
FIBC HANDLING GUIDELINES STORAGE OF EMPTY FIBCs Empty FIBCs and liners should be kept clean and stored undercover in such a manner that accidental damage, exposure to sunlight and extreme climatic conditions are avoided. Examine FIBCs carefuly before using them, if not stored under appropriate conditions. FILLING FIBCs FIBCs are preferably filled with the base of the FIBC supported by the ground or a pallet, and the body of the bag supported by the top lift device. If the FIBC has a discharge spout, it should be tied off or closed before filling. Avoid filling FIBCs with extreme pressure or sudden loads.
STABILITY OF FILLED FIBCs When filled, the ratio of the height of the bag to the width/diameter of the bag should not be more than 2:1. Stability of the FIBC may be improved by vibration during or after filling. LIFTING FIBCs When lifting FIBCs with a forklift truck, be sure that the forklift tines are spaced correctly. All lifting loops, sleeves, or other lifting devices should be vertical, so that no lateral forces will be created in the FIBC. Be sure that the lifting loops are not twisted (except wide cross corner loops). Forklift tines should have round edges or protective covers. FIBC should be raised or lowered smoothly.
HORIZONTAL CARRYING WITH FORK LIFT TRUCKS The forklift truck must be suitable for the load to be carried. When travelling with a FIBC hanging from the forklift tines, there is a danger of the truck becoming unstable. The FIBC must be held close to the mast and as low as possible with the mast tilted slightly backwards. Make sure that the FIBC body will not be damaged by the wheels of the truck. The FIBC should not restrict the view of the driver. FIBCs must not be dragged. The truck should stop before the FIBC is raised or lowered.
HANDLING FIBCs WITH CRANES OR HOISTS The hooks, spreader bars, or other devices used for lifting should have rounded edges and/or protective covers. ATEA recommends the use of safety hooks with an integrated latch to prevent the loop from accidentally slipping off the hook. Hooks should have a sufficiently large radius to prevent squeezing the loop. When the FIBC is suspended, the loops must be vertical, without any twists or knots.
RIGHTING FIBCs To right an FIBC that has toppled on its side, an endless woven sling, wound through all the lifting loops should be used. Any attempt to lift the FIBC using fewer loops than provided may result in the loops being torn off. The risk of such tear may be reduced by using FIBCs with top perimeter band.
STORAGE OF FILLED FIBCs If FIBCs are stored outside, attention should be paid to the top closure. Be sure that the top closure is properly tied off. FIBCs should be covered with waterproof, UV protective material to avoid water collecting on top of the FIBC and to prevent damage from sunlight. FIBCs stored outside without proper coverage are out of manufacturer’s guarantee.
EMPTYING FIBCs FIBCs are usually emptied by gravity, but can also be emptied by suction. When emptying an FIBC by gravity through a bottom discharge spout, the rate of discharge can be controlled by restricting the outlet using various means like b-locks or fix locks. Flow can be stopped by lowering the FIBC onto the discharged load. FIBCs with a plain bottom can be emptied by cutting the base of the bag. Again, the flow can be stopped by lowering the bag onto the discharged load. No one should stand under an FIBC during discharge. A bottom discharge spout should be opened only when the FIBC is suspended over a safety support, that will prevent injury to the operator in the event of a failure of the lifting device. Under no circumstances should anyone stand underneath a suspended FIBC, or place their arm beneath an unsupported FIBC.
STACKING OF FILLED FIBCs When stacking filled FIBCs two or more high, every effort should be made that the stack is stable. Where possible, the stack should be formed against at least two retaining walls, preferably three, to achieve maximum stability. Generally the higher the stack, the greater the number of walls required. Where only free stacking is possible, a pyramid method should be used. FIBCs should not be pushed into a stack as this can cause damage to the sides or back of the FIBC.
Do observe the handling instructions on the FIBC label. Do protect the FIBC from rain and prolonged exposure to sunlight. Do check that the discharge spout is closed off before filling. Do ensure that the filled FIBC is stable. Do close the filling spout correctly, preferably swanneck tied. Do inflate the in-liner prior to filling. Do take the appropriate measures in regard to dust control. Do ensure that the edges of the forklift tines are smooth or protected. Do adjust forklift tines to the correct width for the FIBC being handled. Do keep the forklift tines on the forklift level. Do ensure that the crane hooks are of adequate size and well rounded. Do consider the possibility and effects of static electricity. Do ensure that FIBCs are adequately secured in transportation. Do dispose of FIBCs in accordance with ecological requirements.
Don’t exceed the Safe Working Load under any circumstances. Don’t fill FIBCs unevenly . Don’t stop or start suddenly during FIBC handling and transportation. Don’t subject FIBCs to sudden lifts or stops. Don’t allow personnel under a suspended FIBC. Don’t allow the FIBC to project over the side of a vehicle or pallet. Don’t tilt the mast of the forklift forward. Don’t withdraw forklift tines prior to relieving all the load on the lifting device. Don’t stack FIBCs unless sure of stability. Don’t use damaged FIBCs. Don’t use single trip FIBCs more than one time. Don’t use multitrip FIBCs without checking damage which may have occurred during previous usage. Don’t drop FIBCs when full. Don’t use conductive FIBCs without grounding.
ATEA and Inter-Link Packaging Solutions We look forward to working with you on your industrial packaging needs