This article will take an in-depth look at barrels
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Plastic and metal barrels are cylindrical containers used to store a variety of liquids, solids, and powders for shipping and warehousing. They serve countless purposes, from capturing rainwater to transporting gas and oil. Historically, barrels were made of wood and bound with metal bands, a design that has been in use for centuries.
Modern barrels have transitioned from wooden sides to more durable materials such as metal and plastic, which offer greater strength and longevity. Although the terms "drum" and "barrel" have different historical origins, they are often used interchangeably today. Traditionally, "drum" referred to a 55 US gallon container, while "barrel" denoted a 42 US gallon oil container. As the applications of barrels and drums have broadened, these terms have evolved in their usage.
Plastic barrels are commonly made from high-density polyethylene (HDPE), which is known for its high molecular weight and density. This material is strong, inert, and resistant to both high and low pH values. Barrels play a crucial role in the supply chain, including transport, shipping, storage, and warehousing. Regulatory standards set by the United States government and the United Nations require barrels to display specific letters and numbers to indicate their class and other relevant information.
Barrels generally fall into two categories: closed head and open head. Open head barrels feature a removable cover, making them suitable for applications requiring frequent access to the contents, such as in food production and agriculture. Closed head barrels are fully sealed and typically used for shipping liquid products, featuring two access plugs on the top.
Plastic and metal barrels are essential for storage and transportation because they can hold a wide range of substances. When properly sealed, they protect their contents from environmental conditions and contaminants. Choosing the right type of barrel involves considering several factors beyond the contents, including the barrel's size, shape, material, and intended use.
The material to be transported or stored in a barrel is crucial in determining the appropriate type of barrel. Substances vary widely in their properties; some may be corrosive, acidic, alkaline, liquid, or powdered. These characteristics should be considered by barrel manufacturers when selecting the barrel material to ensure compatibility and safety.
Metal barrels, often referred to as steel or carbon steel barrels, typically feature phenolic linings or rust inhibitors to preserve the quality of the contents. This protection makes them suitable for handling more abrasive chemicals, making them ideal for substances such as retail inks, detergents, and lubricants.
Plastic barrels offer a high degree of versatility in drum packaging. Commonly made from HDPE or LDPE, blue plastic barrels and other plastic drums are often light-blocking and UV-resistant, with molded-in colors. They can store a wide range of materials, including chemicals, medications, food, beverages, cosmetics, electrical components, hardware, and home goods.
When selecting a barrel, it is crucial to consider both the weight of the contents and the barrel itself. Lightweight materials can be accommodated by lighter barrels, while heavier substances may require more robust, heavy-duty drums to ensure safe and secure handling.
The terms "open head" and "closed head" refer to different styles of barrel lids. An open-head barrel features a removable lid, allowing easy access for filling or emptying the barrel. While the lid can be taken off, it can also be securely fastened with clamps, seals, security levers, or locks. In contrast, a closed-head barrel, or tight-head drum, has a fixed lid that cannot be removed. To fill or empty a closed-head drum, the top cover must be removed, as it is permanently attached to the drum’s body.
A closed-head drum, which has a permanently attached lid, can only be opened by force, potentially compromising its UN rating. Once the lid is forcibly removed, the drum is generally considered suitable only for disposal or burning.
The open-head steel drum is ideal for situations requiring quick or easy access to contents. Although it is designed to hold solids or semi-solids and can retain liquids, it is more prone to leaks or spills compared to the tightly sealed closed-head drum. Closed-head barrels, designed to contain liquids, especially thin ones prone to spillage, offer superior leak prevention due to their complete sealing, except for a small bung or aperture.
When selecting a barrel pump, it is important to consider the specific gravity and viscosity of the fluids being transferred. The design of some barrels includes a tap for accessing contents, which can affect the functionality of the barrel’s output valves, if present.
55-gallon drums are constructed with walls designed to withstand specific temperature ranges. It is essential to account for the maximum temperature of the fluids held in the barrel to ensure the drum's suitability for the application.
Sticking to a budget is crucial when purchasing a barrel. The cost of a barrel does not always correlate with its durability, so it’s important to find a balance between cost and quality.
Barrels are available in a variety of sizes and shapes, tailored to the types of products being shipped. Advances in high-density plastics have enabled the creation of numerous shapes and sizes.
Common sizes for HDPE barrels include 55-gallon, 30-gallon, and 15-gallon options, with other sizes available upon special order or from specific manufacturers. While 55 gallons is typically the largest standard size, HDPE barrels can range from 65 gallons up to 95 gallons. The diameters of plastic barrels vary, with a 15-gallon barrel measuring around 14 inches and a 55-gallon barrel reaching up to 23.3 inches in diameter.
Similar to plastic drums, metal drums initially focused on the 55-gallon size but now come in a diverse range of sizes. Unlike plastic drums, metal barrels are typically limited to the traditional cylindrical shape. They also offer various accessories that enhance functionality, such as mixing attachments, strainers, and heaters, which can facilitate easier access and expand their use.
Metal barrels range in size from 5 gallons to 110 gallons, with common increments of 8, 10, 16, and 20 gallons. An important consideration in selecting metal barrels is the number that can fit on a pallet, which influences the selection process based on the material to be handled.
Metal barrels are constructed from carbon steel or stainless steel, with stainless steel typically used for shipping and storing chemicals. Steel barrels are versatile and commonly used for mixing, storing, dispensing, and filtering both liquids and solids, though they are more frequently employed for liquids. Their strength and cost-effectiveness allow producers to utilize them multiple times before recycling once their service life is complete.
Carbon steel consists of iron with carbon content ranging from 0.12% to 2%, which affects its quality and grade. Stainless steel contains between 10.5% and 11% chromium, along with other alloys that enhance its strength and resistance to chemicals, corrosion, and other environmental factors. Common manufacturing processes for these steels include cold rolling and hardening.
Carbon steel is frequently used for shipping hazardous chemicals in industries such as chemical processing, pharmaceuticals, petrochemicals, and wastewater management. Cold-rolled carbon steel is preferred for applications requiring high tensile strength, such as in mining and defense. Stainless steel, on the other hand, is ideal for applications needing high corrosion resistance and sanitary conditions, including food and beverage processing, industrial manufacturing, and construction.
In the food and beverage industry, metal barrels are valued for their strength and durability. Their robustness makes them suitable for industrial applications where they must endure extreme conditions and withstand impacts during shipping. Metal barrels are also UN-approved for handling hazardous materials like acetone, ethanol, and methanol, which can degrade plastic barrels.
Specially designed metal barrels are used to transport flammable, toxic, and hazardous waste products for disposal. These barrels feature tight seals to prevent leaks and rugged exteriors for added protection. The flexibility and durability of steel barrels make them ideal for shipping a wide variety of liquids, powders, and chemicals.
Industrial plastic barrels are made from a range of materials such as polyvinyl chloride (PVC), high-density polyethylene (HDPE), nylon, and polystyrene. These barrels are versatile and can store a wide variety of products, making them highly popular. They are adaptable, durable, cost-effective, and resistant to substances with extremely high or low pH levels.
Plastic barrels, often referred to as blue barrels, are used for a variety of tasks including dispensing, mixing, filtration, transporting, and storing. Available in a range of sizes, they can contain everything from food and beverages to hazardous waste. Applications include shipping and storing food products, chemical oils, vinegar, medications, beverages, and materials like sand. After proper cleaning, these barrels can be recycled and repurposed.
The advent of plastic barrels has broadened the options available to manufacturers and producers for shipping their products. Their diverse sizes and shapes allow for adaptation to various applications, providing a flexible solution for moving goods throughout the supply chain.
Forming is a common method used in the production of metal barrels. Initially, the metal sheet used for each drum is processed through an edge grinder to smooth out any sharp edges. The sheets are then placed into a bender with a cylindrical mold, where they are curved and bent. Various welding techniques are employed next. The bent metal is fed into a spot welding machine, which welds multiple points along the edge of the sheet to form a tube. This tube is then fully seamed together using seam welding equipment, which welds across the entire connection of the sheet ends.
After the drum's body is formed, it undergoes a detailed manipulation process. During the flanging process, the drum is passed through a machine that adds flanges, creating rim indentations and edges on the top and bottom of the container. Following this, the barrel is processed by a bead expander, which stretches beads or rolling hoops around the circumference of the drum. These reinforcing hoops are made by rotating rods inside the barrel. Additionally, circumferential indentations are created along the top and bottom of each barrel using a corrugating machine to enhance the drum's strength and structure.
After the body of the container has been constructed to the specified standards, the bottom section of the container must now be made and then attached.
To ensure that the container does not leak, it is seamed. Next, the container must be completed by adding a top so it can stand alone. Drum bottoms and tops are manufactured in a similar manner. First, the drum tops need to be punched with holes of specified sizes and locations using a machine. The next step involves inserting flanges into these holes. Metal rings are bent inside the holes using a flange-fitting die set or mold machine. These apertures will later allow the drum contents to be emptied into or out of the container. Once completed, the top, equipped with flanged holes, is seamed to the body using a method similar to bottom seaming, resulting in a fully functional container. The steel barrel is now complete.
However, optional procedures are employed in the fabrication of steel drums depending on personal preferences and intended use. For example, each drum may be placed in a paint booth machine, where it is rotated and horizontally fed while being painted on the exterior by the machine.
Plastic blow molding technology is used to produce plastic barrels by blowing molten plastic into a die or mold. This method allows for the creation of various shapes without internal seams. Like steel drums, plastic barrels are typically formed in a cylindrical shape to facilitate rolling and handling. This round design avoids weak corners, although exposed and impact-prone areas may still be susceptible to cracking. The seamless construction of blow-molded barrels also helps prevent the growth of microorganisms in crevices. The range of sizes and shapes achievable through blow molding is virtually limitless. Materials commonly used for blow molding drums include thermoplastics such as acetal, polyamide, polystyrene, polyvinyl chloride, low or high-density polycarbonate, and polypropylene.
Blow molding can be performed in three methods: extrusion, injection, and injection stretch. Each method begins with melting resin or pellets to form a parison, a long plastic tube with a hole at one end. This parison is inserted into the mold cavity, open end first, and securely clamped to prevent air leakage. Compressed air is then used to inflate the parison, pressing it against the mold's sides. As the heated plastic expands, it fills the mold and takes on its shape. Once the plastic has cooled, the mold is opened to release the finished barrel. Any top and bottom protrusions from the barrel can be removed either automatically or manually.
The top cover of a closed-head barrel, also known as a tight-head drum, is non-detachable. Both the top and bottom of a plastic drum with a tight head are sealed. The top side of a closed-head drum, similar to the bottom, forms a durable seal as it is solidly integrated with the drum's body. Access to the contents of a closed-head drum is provided through a port known as a bung opening. These small openings are sealed with a bung or another sturdy stopper. Tight-head plastic drums are often considered more secure than open-head plastic drums due to their sealed nature.
Closed-head drums are ideal for storing low-viscosity liquids such as water, gasoline, crude oil, and other flammable and liquid combustibles. The two-inch bung is designed to accommodate appropriate pipe and pumping systems, ensuring secure loading and spill-free filling. Since closed-head drums are frequently used for storing hazardous liquids, they are typically UN-rated, feature the appropriate hazmat labeling, and must meet stringent regulations.
An open-head barrel, also known as an open-top drum, features a top cover or lid that is completely detachable. These drums can be sealed with a tight cover and fastenings for transport or storage, or they can be left open-topped without a lid. The top of the container serves as the entry point for filling and emptying.
Open-head barrels are designed to withstand the rigors of shipping and are built to endure harsh environments and continuous use. They are versatile and durable, suitable for both indoor and outdoor applications depending on the project’s requirements.
Due to their reliability and durability, open-head drums are commonly used for shipping and storage. They can be filled and emptied without the need for special tools or equipment and can be manually loaded or unloaded if necessary. Manufacturers often produce these drums in various colors for inventory purposes, and their smooth surfaces can be labeled to identify the contents.
Open-head barrels are used because they offer several advantages, including:
Taper-sided barrels are lighter and easier to handle compared to other types of drums. Their tapered design also allows for efficient nesting, simplifying storage. Open-headed taper-sided 55-gallon drums are commonly available in various colors, with blue being the most typical.
Stainless steel drums are becoming increasingly popular in the wine industry for creating, fermenting, maturing, and storing wine. New designs are specifically engineered to fit inside wine barrel racks.
Rain barrels are containers designed to collect rainwater that drips from roofs and downspouts. Although this collected water is not safe for consumption due to being non-potable, it is suitable for washing vehicles, cleaning outdoor surfaces, and watering gardens, lawns, and trees.
Rain barrels feature a simple design and are easy to use and place. Installing a basic rain barrel helps utilize soft rainwater, reduces reliance on public utility water, and promotes self-sufficiency. Additionally, rain barrels help reduce the volume and flow of runoff into sewer or stormwater systems by capturing and storing rainwater.
Metal barrels can be constructed from various materials, each with different strengths, making them suitable for storing a wide range of substances. Knowing the material to be stored is essential for selecting the appropriate type of barrel. Metal drums are commonly used for various purposes and are effective for both long-term storage and transportation. Some of their most common applications include:
It is essential to ensure that the barrels used can accommodate the materials they are intended to hold, as plastic barrels come in various grades, strengths, and capacities. Additionally, approved polymers are required for storing chemicals and other hazardous materials.
Steel barrels are one of the most widely used industrial storage solutions today, offering numerous advantages to organizations. Some of these benefits are outlined below.
Steel drums or metal barrels are known for their strength and durability. They are particularly effective at preventing damage to or contamination of the items stored inside. Steel barrels are versatile and suitable for holding a wide range of materials, from pharmaceuticals to hazardous waste.
In the food and beverage supply chain, steel barrels remain a popular choice due to their durability. They help safeguard and keep food products fresh, especially when used with drum liners. It is important to ensure that the steel barrel is certified as "food grade" and has not previously contained potentially hazardous substances before storing food products.
Steel barrels are excellent for storing items due to their ease of maintenance and simplicity of use. In fact, with proper care and attention, including regular cleaning, a steel drum can last for decades.
Steel barrels should be cleaned after each use, but don't worry—they are easy to maintain. After emptying, you can clean them with standard cleaning supplies, depending on the contents they held.
Steel barrels are highly reusable because they are easy to clean and maintain. By extending their use, you can reduce operating costs and support environmental sustainability. Additionally, at the end of their long lifespan, steel barrels can be fully utilized or disassembled and recycled into new barrels.
Metal barrels provide protection against physical damage, airborne contaminants, moisture, UV rays, and pests when securely sealed. For added defense, you can apply waterproof coverings, UV-resistant coatings, or other protective layers, especially if the barrels are stored outdoors.
Metal barrels can be customized extensively to simplify storage, handling, and shipping over long distances. For example, many barrels feature sturdy handles that enable easy movement without heavy equipment.
Steel drums can also be equipped with various accessories. The most common is a drum liner, which fits inside the barrel to prevent contamination between the stored product and the steel.
Metal barrels are designed for industrial use and are built to be stackable. While they are large and heavy when filled, they can be easily lifted and moved with equipment like forklifts. Their stackable design allows for efficient storage in warehouses and easy transportation in trucks, helping to save space, time, and money.
Plastic barrels are more lightweight and portable compared to metal drums. Below are some additional advantages of using plastic barrels.
Plastic is a highly durable and resilient material. Plastic barrels are made from strong materials that extend their lifespan. They resist weathering, temperature fluctuations, and damp or humid conditions. Additionally, plastic is resistant to ultraviolet radiation, making outdoor storage feasible. The robust seal of plastic drums ensures they remain leak-proof and secure during storage and transport. The strength and durability of plastic set it apart from other materials.
Plastic barrels can be customized to accommodate various substances and are mass-produced in multiple sizes, offering excellent value.
Another advantage is that recycled plastic barrels help reduce landfill waste. With numerous applications, plastic barrels can be repurposed, significantly mitigating one aspect of the growing waste management challenge.
The polymers used in plastic barrels are inert and resistant to both low and high pH levels. This makes them an ideal choice for storing and transporting chemicals and other potentially volatile materials.
Plastic barrels are cost-effective, which has contributed to their popularity. They quickly gained favor due to their affordability and practicality compared to glass, metal, or other materials. Additionally, plastic barrels can endure years of use without showing signs of wear or damage.
Sustainability refers to the ability to preserve and maintain our way of life for future generations. Plastic barrels exemplify this concept as they can be repurposed and reused in numerous ways after their initial industrial use. Unlike steel and aluminum, which require complex and time-consuming recycling processes, plastic can be easily recycled and converted into plastic pellets by shredding. This makes plastic barrels a more sustainable choice compared to other materials.
An emerging industry focuses on repurposing, reconditioning, and refurbishing discarded drums that have outlived their industrial use. Despite no longer serving their original purpose, these drums remain sturdy and viable. The repurposing process involves a series of detailed steps to ensure the drums are safely adapted for new applications.
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