This article contains information in regards to 55 gallon plastic drums and their use.
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A 55-gallon plastic drum is a sturdy container, designed for storage or transportation, made from tough, high-density industrial-grade polymer. With their thick walls, these drums provide exceptional durability, strength, and longevity, making them ideal for safely holding a wide range of substances and materials. The seamless construction enhances their suitability for securely containing hazardous or harmful solids and liquids.
Recognized for their strength and durability, 55-gallon plastic drums have become essential across various industries, including distribution, shipping, and storage. Their robust construction makes them especially useful in sectors such as chemical handling, food processing, and manufacturing.
The manufacturing process for 55-gallon plastic drums begins with selecting the appropriate high-density polymer, typically high-density polyethylene (HDPE) or sometimes linear low-density polyethylene (LLDPE) for specialty drum applications. These polymers are chosen for their exceptional impact resistance, chemical stability, and suitability for storing and transporting industrial liquids, food-grade products, hazardous materials, oils, chemicals, and pharmaceuticals. Raw materials for drum production start as either resin pellets or granules, which can be derived from recycled plastics or newly synthesized virgin resin, meeting strict quality and regulatory standards for the intended end use.
Although resin materials may appear similar, their molecular structure, strength, and density can differ significantly based on type and grade. Resins are initially viscous substances that become rigid polymers through the polymerization and curing process. In modern drum manufacturing, synthetic resins such as HDPE are preferred, as they offer superior mechanical properties, durability, and chemical resistance—important characteristics for the safe long-term storage and transportation of both hazardous and non-hazardous liquids. Drums manufactured using food-grade resins also comply with FDA and USDA requirements, which is essential for applications requiring hygienic packaging.
The three primary processes used to produce 55-gallon plastic drums are rotational molding, injection molding, and injection blow molding. Of these, injection blow molding is the most prevalent and efficient, suitable for creating seamless, durable, and highly consistent drums. In both blow molding and injection molding, resin pellets are melted and injected or extruded into a drum-shaped mold cavity, forming a monolithic, leak-proof vessel. Rotational molding, suited for low to medium production volumes or custom drum designs, utilizes resin powder loaded into a rotating heated mold to achieve uniform wall distribution and complex geometries. These advanced plastic manufacturing methods support drum customization for UN/DOT compliance, stackability, and tamper-evident seals—key selling points for buyers in the industrial packaging market.
Resin pellets, the foundational material for 55-gallon plastic drum production, typically appear clear or white but can be compounded with colorants or additives to produce drums in a wide spectrum of colors. Standard colors such as blue, white, yellow, and black are commonly available for quick shipment, while custom hues can be provided for brand differentiation or identification purposes. During the extrusion or molding process, these resin pellets are melted and shaped into a parison, a hollow tube that serves as the precursor to the final drum shape.
To maximize the durability and longevity of 55-gallon plastic drums, manufacturers add specialized UV stabilizers and inhibitors to the resin pellets. These additives safeguard the drums against the damaging effects of prolonged sunlight exposure, such as brittleness, discoloration, or structural degradation. Among the color options, black plastic provides the highest UV protection and is often preferred for outdoor storage, while lighter colors, such as white or natural, may offer less resistance and are best suited for indoor or short-term use. This level of customization ensures buyers can select the right drum for their storage environment and contents.
Blow molding is the predominant and most efficient method for manufacturing 55-gallon plastic drums, offering consistent wall thickness and structural integrity. The technique begins by placing the parison into a precision drum mold, where it is inflated with pressurized air to conform to the internal shape of the mold. There are three main types of blow molding used for plastic drum production:
Each method offers benefits regarding production speed, precision, and cost effectiveness, making blow molded drums the preferred option for bulk liquid transport and hazardous materials packaging where performance and compliance are non-negotiable.
The process commences as resin pellets are introduced into the hopper, either manually or with automated bulk feeding systems for large-scale production. These pellets are then conveyed into an extruder through the feed barrel. Inside the extruder, they are subjected to controlled heating and mixing as they move toward the blow molding die. Advanced heating elements encircle the screw drive, ensuring uniform melting of the pellets so they form a consistent, defect-free parison primed for shaping the drum.
The precision of temperature and feed rate within the plastic extruder is vital for maintaining the desired physical properties, minimizing resin degradation, and preventing manufacturing defects. The capacity and automation level of the feeder and extruder are important factors buyers often evaluate when comparing different 55-gallon plastic drum suppliers, as they impact both the cost and quality of the final product.
Once melted, the extruder generates a parison, which is carefully positioned into an open, drum-shaped mold designed to deliver the desired capacity and geometric precision for 55-gallon drums. The diagram below demonstrates how the parison takes on a tubular structure, ready to be expanded into the shape of a seamless plastic barrel. Mold design considerations, such as venting, cooling channels, and material flow optimization, ensure uniform wall thickness, structural strength, and leak-proof seams—key quality assurance criteria for end users in industries ranging from food processing to hazardous chemical containment.
The next step in manufacturing involves pressing the die sections together using advanced pneumatic or hydraulic clamping systems. The ends of the parison are sealed firmly between the die halves, with a precisely engineered opening at the top to allow for regulated injection of pressurized air. This ensures the drum will meet strict performance standards for pressure, drop, and leak resistance and is especially important for compliance with DOT/UN ratings for hazardous material containers.
As illustrated below, compressed air is introduced into the parison at controlled high pressure, inflating it against every contour of the mold’s interior surface. This step is crucial for achieving even wall distribution, eliminating weak spots, and ensuring a seamless, defect-free finish. Well-controlled blow molding prevents bubbles, pinholes, or inconsistencies that could otherwise compromise the container's ability to safely store liquids, chemicals, or hazardous waste products.
Once the drum has cooled and achieved its final rigid form, the mold halves are separated—automatically in most high-output facilities—using pneumatic or hydraulic motors. The solidified 55-gallon drum is carefully ejected, ready for finishing, quality inspection, and secondary operations such as trimming excess material, adding bung holes, or printing product information on the drum exterior. This efficient process allows manufacturers to offer fast lead times, consistent product quality, and compliance with international packaging regulations, making plastic drums a cost-effective and dependable packaging solution for almost any industry.
For applications requiring custom shapes, thicker wall construction, or smaller production runs, rotational molding is preferred. This method begins with solid resin powder, most often consisting of polyethylene or specialty engineered plastics for unique performance requirements. The powder remains solid until loaded inside a heated mold, providing processors precise control over wall thickness and physical properties.
Rotational molding employs heavy-duty steel or aluminum molds to create hollow, seamless products. Before resin loading, a release agent is applied to ensure easy removal of the finished drum and preserve mold longevity. Certain molds feature draft angles or textured surfaces to aid in demolding without the need for chemical release agents, minimizing potential contamination and maintaining food safety standards. The diagram below shows resin powder carefully added into the prepared drum mold.
With the mold closed, it rotates bi-axially inside an industrial oven, ensuring resin powder coats every surface evenly as the heat gradually melts and fuses it into a continuous layer. As shown in the diagram below, this rotational movement results in a uniform wall structure, optimum durability, and resistance to cracking or punctures. The amount of resin powder introduced directly affects the finished drum’s wall thickness, impact strength, and load-bearing capacity. Manufacturers monitor these variables closely to meet customer specifications for liquid storage, hazardous containment, stackability, and compatibility with filling and dispensing equipment. Because the process allows for intricate shapes and integrated features, rotationally molded drums can be tailored for specialized use cases such as rainwater collection, chemical processing, agricultural supply, and marine applications.
This advanced rotational molding method demonstrates the versatility, cost-effectiveness, and high performance of 55-gallon plastic drums across diverse industries and applications.
Among the various materials used in modern product manufacturing, plastics are recognized as the most versatile and widely utilized substances, catering to a broad spectrum of industrial and domestic applications. Their unique robustness, chemical resistance, and adaptability have positioned plastics as essential materials for an array of products—including 55-gallon plastic drums. These industrial storage solutions are relied upon for the safe storage, efficient transportation, and reliable shipping of a diverse range of goods, whether in hazardous material handling, food-grade storage, or logistics sectors.
For the manufacturing of high-capacity plastic drums, the selected plastics must exhibit exceptional structural integrity, impact resistance, and durability under demanding conditions. This requires polymers with specific mechanical properties and barrier characteristics that can withstand UV exposure, chemical degradation, and extreme temperatures, ensuring the drums remain reliable during long-term use in industrial environments.
While it may appear that all plastics are similar, whether for consumer goods like cups and plates or for more robust and industrial products like barrels and bulk storage containers, there are in fact thousands of distinct plastic types available today. Each variant is formulated from diverse base chemicals, molecular modifications, reinforcement additives, and stabilizers. These variations enable the tailored production of plastics with optimal strength, flexibility, and safety features—ensuring each type of 55-gallon drum aligns with specific requirements such as food safety, hazardous waste containment, or chemical compatibility.
For the manufacturing of 55-gallon plastic drums, the plastics utilized must be exceptionally resilient, strong, and safe for their intended content. The most commonly used polymers include polyvinyl chloride (PVC), high-density polyethylene (HDPE), nylon (polyamide), and polystyrene (PS). Since the 1960s, these materials have replaced steel due to their corrosion resistance, lighter weight, and cost efficiency, making plastic drums the industry standard for many bulk storage and transport applications.
Understanding the unique properties of each plastic type helps buyers, engineers, and compliance officers select the right drum for their storage or transport needs. Factors such as chemical resistance, food-grade certifications, and suitability for hazardous material containment play critical roles in the decision-making process when evaluating different 55-gallon plastic drum options.
Polyvinyl chloride (PVC) is a synthetic resin developed through the polymerization of vinyl chloride monomer. As the second most widely produced plastic resin globally, PVC offers impressive rigidity, tensile strength, and flame retardance. These properties make PVC an excellent choice for drums intended to store flammable, corrosive, or hazardous materials. Its impermeability and weather resistance also enable reliable outdoor storage without the risk of chemical leaching or UV degradation.
High-Density Polyethylene (HDPE) stands out among plastics for its high strength-to-density ratio, impact resistance, lightweight design, and superior chemical resistance. Produced from petroleum through a controlled cracking process to generate ethylene gas, HDPE is polymerized into long molecular chains, resulting in a stable and tough thermoplastic. HDPE is valued for its non-reactivity with a wide range of substances, making HDPE 55-gallon drums the preferred choice for storing acids, caustics, food-grade ingredients, pharmaceuticals, and hazardous materials. They are compliant with FDA regulations for food and beverage use and approved for UN/DOT hazardous material transport applications.
In addition to their impact and chemical resistance, HDPE drums are recyclable and offer excellent longevity for repeated use, further supporting sustainability initiatives and lowering total cost of ownership for industrial packaging operations.
Nylon, known chemically as polyamide (PA), is used in manufacturing certain industrial plastic drums due to its exceptional inertness, low moisture absorption, and high resistance to abrasion and chemicals. These characteristics are critical for applications requiring strict purity and long-term durability, such as specialty chemical storage or pharmaceutical transport. Produced by condensing two distinct types of molecules under heat and pressure, nylon produces a flexible yet extremely tough polymer that can be adapted for various specialty drum designs and closures.
Polystyrene (PS) is another valuable polymer in the drum manufacturing industry. Created by the polymerization of styrene monomers, polystyrene features increased hardness and rigidity when blended with reinforcing polymers. Because of these mechanical strengths, PS can be utilized in drum applications where a rigid, stable structure is essential. Although more commonly recognized in consumer applications like disposable cups, trays, and product packaging, modified polystyrene can be engineered for use in the production of 55-gallon plastic drums where moderate chemical compatibility and robust structural integrity are required.
Modern polystyrene drums are produced using eco-conscious processes that avoid harmful chlorofluorocarbons, aligning with sustainability and regulatory standards within the plastics industry. When blended with other engineered polymers, PS can achieve higher performance criteria, ensuring compliance with storage regulations for industrial and commercial use.
When choosing the optimal type of plastic for a given 55-gallon drum application, it is important to consider requirements like UN/DOT certification, FDA food-grade compliance, and compatibility with the intended contents. End-users often evaluate drums by their resistance to UV radiation, their ability to withstand mechanical impact, and their recyclability or reusability. For safe storage and efficient freight, the right material ensures regulatory compliance and protects both workers and stored materials. If searching for custom drum solutions, consult with a manufacturer to confirm that the selected plastic type meets your specific process, storage, and transport needs.
The application of 55-gallon plastic drums spans a wide range due to their versatility and robust construction. While their diverse uses are frequently discussed, the fundamental purpose of these drums often goes overlooked: they are primarily designed for the storage, transportation, and shipment of liquids, powders, granular substances, chemicals, and food items. These core functions are what have contributed to their widespread adoption over the past sixty years.
The introduction of high-density plastic drums has significantly benefited manufacturing and industrial sectors. Their exceptional durability and strength make them an effective solution for handling potentially hazardous storage conditions.
For a plastic drum to be suitable for food storage or transportation, it must adhere to the cleanliness and sanitary standards set by the Food and Drug Administration. The designation "food grade" refers to plastics that are safe for direct contact with food throughout its processing, harvesting, production, or packaging stages. In the case of 55-gallon plastic drums, they have been certified as safe for the long-term storage and transport of food products.
To earn the food grade designation, 55-gallon plastic drums undergo rigorous testing, inspection, and analysis to ensure that they are free from harmful dyes or chemicals. Once a drum meets these stringent criteria, it is deemed suitable for storing bulk foods, grains, liquids, and cooking oils.
The pharmaceutical sector depends on 55-gallon plastic drums for their robust construction and resistance to corrosive substances. Drums used in this industry are crafted from high-density, FDA-compliant polyethylene, which provides excellent protection against chemicals and hazardous materials.
The secure seal of these 55-gallon plastic drums safeguards their contents from environmental factors and contaminants, ensuring the integrity and purity of the stored materials.
Among various chemical storage solutions, 55-gallon plastic drums stand out as the safest and most dependable choice. Storing hazardous and volatile chemicals requires meticulous planning and high-quality plastic materials due to the risks involved. A primary concern is preventing the exposure of toxic substances to the environment. With their tight seals and resistance to rust and corrosion, 55-gallon plastic drums offer optimal protection from environmental factors, extreme temperatures, and proximity to other chemicals.
Disposing of industrial waste demands careful and strategic handling to mitigate environmental harm. The design of 55-gallon plastic drums makes them an excellent choice for securely and efficiently managing industrial waste. Their robust construction and secure seals ensure that hazardous substances remain contained, preventing any potential environmental impact.
The durability and versatility of 55-gallon plastic drums have made them the preferred option for companies seeking environmentally-friendly waste management solutions. With a range of materials and designs available, these drums can be tailored to accommodate various types of waste, supporting sustainable waste management practices.
Plastic 55-gallon drums have become essential in the oil and petroleum industry. Before pipelines were introduced, crude oil was transported in drums. Initially, these drums lacked the durability needed and often leaked or broke during transit, prompting the shift to more robust steel drums.
Although steel drums addressed many issues, disposing of them after use posed significant challenges. This problem persisted until the advent of the plastic 55-gallon drum. Introduced in the 1960s, the first HDPE 55-gallon drum represented a significant advancement, offering a more practical solution for storing and transporting oil byproducts.
Historically, wine was fermented and stored in wooden barrels for centuries, which later transitioned to stainless steel containers. However, the introduction of FDA-approved food-grade 55-gallon plastic drums has led the wine industry to increasingly favor plastic for fermentation and storage. Polyethylene drums, known for their chemical resistance and durability, are preferred.
Manufacturers have found that plastic drums are more cost-effective to clean, occupy less space, and are lighter, making them easier to handle. The adaptability and high performance of 55-gallon plastic drums have made them a practical alternative to traditional wooden casks.
Beyond their primary applications for storing and shipping various substances, 55-gallon plastic drums have seen a surge in unconventional uses once they are no longer needed for industrial purposes. An array of creative and unexpected applications has emerged, with manufacturers even designing drums to cater to these specific needs.
Among the innovative uses for 55-gallon plastic drums are rainwater collection, composting, garden planters, support for hydroponic systems, aquaponics, root cellars, buoy markers, and even wheelbarrows. Although these uses might seem unconventional, they represent valuable ways to repurpose drums for beneficial and inventive applications.
55-gallon plastic drums are available in various types, depending on the material used and the wall thickness. Each type is tailored for specific applications, such as those designed for handling chemicals and hazardous materials, versus those intended for powders and food products.
The distinction among these drums primarily lies in the type of polymer used in their construction, with High-Density Polyethylene (HDPE) being the most prevalent. In addition to material differences, 55-gallon drums are categorized by their type of head, which can either be an open removable lid or a closed, sealed top. The choice of head type is as crucial as the material, reflecting the drum's intended use.
Open-head 55-gallon plastic drums are approximately 35 inches tall with a diameter of 23 inches. These drums feature a removable cover secured by a lever or bolt ring mechanism, ensuring a tight seal when the drum is closed. The lid is designed for easy removal, allowing for straightforward loading and access. Open-head drums are ideal for situations where frequent and unrestricted access to the contents is needed.
Open-head 55-gallon plastic drums generally have a height of about 35 inches and a top diameter of 23 inches. They feature a removable cover that is secured with either a lever or bolt ring mechanism to ensure a tight seal when not in use. This design facilitates easy and frequent access to the drum's contents, making these drums well-suited for applications that require regular access.
The lids for 55-gallon plastic drums come in various styles to suit different drum configurations. Steel lids are notable for their durability and strength, often fitted with an EPDM rubber gasket for a secure seal. Lids made from low-density polyethylene (LDPE) are favored for their flexibility and ease of molding, as well as their resistance to heat and moisture, which makes them ideal for open-head drums. In some cases, lids are made from vinyl or high-density polyethylene (HDPE) for added UV protection.
Closed or tight head drums differ from open head drums in that they are completely sealed, with access provided through a top opening and a smaller vent hole. Typically, these drums measure 35 inches in height and have a 23-inch diameter. Both the top and bottom of the drum feature flanges and are permanently sealed as part of a single-piece design.
This design is specifically suited for safely transporting and containing hazardous substances that could be volatile if exposed to air. Closed head drums are ideal for securely shipping waste and unstable materials and are generally used for handling liquids with various viscosities.
Closed head drums feature two threaded openings on the top: one for ventilation and the other for content access. The material of these bung holes, either plastic or metal, is selected based on the type of material contained in the drum.
55-gallon drums have become the preferred choice over aluminum and steel drums for storing and shipping granular, powder, and liquid substances due to their numerous advantages. Since their introduction in the 1960s, plastic 55-gallon drums have quickly become the top choice for barrel and drum storage.
Plastic's ability to be easily repurposed and recycled sets it apart from other materials used in drum manufacturing. While aluminum and steel can also be recycled, the processes involved are often complex and labor-intensive. In contrast, plastic drums can be efficiently shredded and converted into plastic pellets with relatively less effort.
Plastic drums are crafted from highly durable materials, extending their lifespan significantly. The robust nature of plastic 55-gallon drums makes them resistant to various environmental factors such as weather changes, temperature extremes, and high humidity. Additionally, plastic is unaffected by ultraviolet rays, eliminating concerns about sun exposure. The secure seal of plastic drums ensures that they remain leak-proof and do not sweat during storage or transport.
Sustainability is a key concept in modern business, focusing on preserving resources for future generations. Once plastic drums have outlived their industrial use, they can be repurposed in numerous ways, from garden planters to being ground into pellets for new products. This versatility highlights the environmental benefits of plastic drums throughout their entire lifecycle.
Repurposing 55-gallon plastic drums offers the added advantage of preventing them from ending up in landfills or waste dumps. Their versatility in reuse reduces the need for disposal methods, addressing a significant aspect of the growing waste management challenge.
The polymers used in manufacturing 55-gallon plastic drums are chemically inert and resistant to both low and high pH levels. This makes them well-suited for the safe shipping and storage of chemicals and potentially volatile substances.
The primary reason 55-gallon plastic drums have become so valuable is their cost-effectiveness. Upon their introduction, they were quickly adopted due to their affordability compared to glass, metal, or other storage materials. Plastic is simpler, more economical, and more practical to produce. These drums can be used for years without showing signs of wear or damage. The durability and resilience of plastic distinguish it from other materials.
Manufacturers of 55-gallon plastic drums fully understand the numerous advantages of their products. Engineers and experts involved in designing and producing these drums recognize that they provide a safe, secure, and airtight solution for shipping and storing a variety of materials. They collaborate closely with customers to ensure that the containers meet specific shipping requirements precisely.
The United States Department of Transportation has set standards for shipping containers that all manufacturers, producers, and industries must adhere to. Alongside national regulations, the United Nations has developed a rating system for shipping containers that companies should follow for international shipments of liquids, substances, and other materials. A container with a higher UN rating can comply with lower rating regulations but cannot be used for applications exceeding its rating level.
The UN system uses a series of numbers and codes to identify and rate containers. For a 55 gallon plastic drum, this rating follows a specific sequence. The example below provides a brief overview of how a 55 gallon plastic drum is categorized under the UN rating system.
1H2/X420/L
1 – The number one in the first position of the UN system signifies that the container is a drum.
H – The letter "H" in the second position indicates the type of material used to make the container, which is plastic in this case.
1 or 2 – The third position denotes whether the drum is open or closed head, with 1 representing closed head and 2 representing open head.
X – The "X" following the backslash shows the packing group for which the container is rated. There are three groups: Roman numeral I for highly hazardous materials, II for moderately hazardous materials, and III for the least hazardous materials.
420 – The final number following the "X" specifies the gross mass that the container is rated to handle. This weight includes both the container and its contents, and has been tested and approved for safety.
L – The letter "L" after the second backslash denotes the type of contents the container is rated for, with "L" indicating liquids. The alternative "S" would stand for solids.
The UN rating system aims to ensure safety, protect the environment, and help companies avoid costly penalties. UN ratings are valid for five years, after which an extension may be requested from the Department of Transportation (DOT). If an extension is not requested, the UN-rated drums should be properly disposed of.
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