This article will take an in-depth look at barrels
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Plastic and metal barrels are cylindrical containers designed to store diverse types of liquids, solids, and powders for shipping and storage purposes. Their uses are extensive, ranging from collecting rainwater to transporting oil and gas. Initially made of wood bound with metal strips, barrels have been utilized for centuries.
Over time, the original wooden barrels evolved, with their sides being replaced by more durable and sturdy materials such as metal and plastic. Although originating from different backgrounds, the terms "drum" and "barrel" are now often used interchangeably. Traditionally, "drum" referred to a 55 US gallon container while "barrel" denoted a 42 US gallon oil container. As their applications broadened, the definitions of these terms have adapted.
Plastic barrels are crafted from high density polyethylene (HDPE), which boasts high molecular weight and density. It is an incredibly robust material that is neutral and resistant to extreme pH levels. Barrels serve numerous functions across the supply chain, from shipment and transportation to storage and warehousing. Both the United States government and the United Nations have set forth regulations and standards that require specific markings on barrels to determine their classification and other essential information.
Barrels are generally categorized into two types: open head and closed head. Open head barrels have removable covers, making them suitable for scenarios requiring frequent content access, such as in agriculture and food production. In contrast, closed head barrels—ideal for transporting liquids—are completely sealed and include two access plugs at the top.
Due to their versatility, plastic and metal barrels are indispensable for storage and transportation, capable of safely holding nearly any substance. When secured correctly, barrels safeguard their contents against contamination and environmental elements. Selecting the right barrel involves several considerations beyond what's stored inside, like size, shape, material, and intended use.
The contents that a barrel needs to transport or store play a crucial role in determining the material used for the barrel. Some contents might be corrosive, while others are neutral, and some could be acidic or alkaline. These characteristics must be considered by barrel manufacturers when deciding on the appropriate material.
Commonly referred to as steel or carbon steel barrels, metal barrels are equipped with either phenolic linings or rust-inhibiting interiors to preserve the contents' quality. This protection renders them ideal for handling more abrasive chemicals, making them suitable for items such as retail inks, lubricants, detergents, and more.
Plastic barrels offer the widest range among drum packaging options. Often made from either HDPE or LDPE, plastic drums come in diverse colors with UV-resistant and light-blocking features. They can safely transport a wide variety of liquids and solids, such as chemicals, food, beverages, cosmetics, pharmaceuticals, electronics, and household products.
The combined weight of the contents and the barrel is crucial when choosing the right barrel. While lighter contents might be stored in lightweight materials, heavy contents necessitate a more robust barrel.
"Open head" and "closed head" refer to two distinct barrel lid designs. An open head barrel has a detachable lid, allowing full access for filling or emptying. The lid, while removable, can be securely attached using clamps, seals, or locks. Conversely, a closed-head barrel, also known as a tight-head drum, has a permanently sealed lid, requiring removal to access the contents.
Should a closed head drum's lid be forcibly removed, it loses its UN rating and is relegated to use as a burn or trash barrel.
The open-head design is preferable for scenarios needing quick or regular access to the barrel's contents. While it can store liquids, its design is better suited for solids or semi-solids. In comparison, closed-head barrels offer superior leak protection, making them ideal for holding liquids, especially those with low viscosity.
Before selecting a barrel pump, it's important to consider the viscosity and specific gravity of the fluids involved. This choice will influence the design of the barrel's output valves, if present, particularly for barrels equipped with access taps.
Barrels, particularly the 55-gallon type, are built to withstand specific temperature ranges, thanks to the materials utilized in their construction. Hence, understanding the maximum temperature of the fluids is vital when choosing a barrel for particular applications.
When purchasing a barrel, it is essential to adhere to a predetermined budget. Keep in mind that a higher price does not always equate to greater durability.
Barrels are available in numerous shapes and sizes. The diversity in barrel size has evolved to accommodate different products requiring transport. Additionally, high-density plastics enable manufacturers to produce a wide variety of forms.
Typical HDPE barrel sizes include 55 gallons, 30 gallons, and 15 gallons, with other sizes available upon special request or varying by manufacturer. Though 55 gallons is commonly the largest size, some HDPE barrels can expand up to 65 or 95 gallons. Plastic barrels' diameters range from 14 inches for a 15-gallon barrel to 23.3 inches for a 55-gallon barrel.
Metal barrel sizes, beginning from the traditional 55-gallon drum, have expanded to encompass a wide size range. Unlike plastic barrels, however, they maintain the classic cylindrical form. Various accessories enhance metal barrels' utility, such as strainers, mixers, and heaters, facilitating easier content access and increased functionality.
Metal barrel size options start at 5 gallons and can extend up to 110 gallons, with increments of 8, 10, 16, and 20 gallons. The selection process for metal barrels often takes into account how many barrels can be stacked on a pallet, which helps guide decisions based on the materials to be handled.
Metal barrels, commonly referred to as steel drums, are manufactured from premium-grade carbon steel and stainless steel. Stainless steel drums are particularly essential for the shipping and storage of chemicals, including hazardous and corrosive materials, due to their exceptional chemical resistance and hygienic qualities. Across industries, steel barrels are relied upon for the handling of both liquids and solid materials during mixing, storage, dispensing, filtration, and transportation processes. The robust construction and economic value of these barrels allow producers to achieve multiple life cycles from a single barrel before it is recycled, making them both cost-effective and environmentally friendly.
Carbon steel is an alloy made primarily of iron, containing between 0.12% and 2% carbon content. The exact percentage of carbon influences the strength, durability, and grade classification of carbon steel barrels, impacting their suitability for various industrial applications. Stainless steel, on the other hand, is alloyed with a minimum of 10.5% chromium, often supplemented by additional alloys to enhance corrosion resistance, tensile strength, and resistance to harsh chemicals and environmental conditions. Manufacturing processes such as cold rolling and hardening are commonly used to improve the strength and longevity of both carbon and stainless steel drums.
For shipping and storing hazardous chemicals used in chemical processing, as well as in sectors such as pharmaceuticals, petrochemicals, mining, defense, wastewater treatment, and industrial manufacturing, carbon steel barrels are the industry standard. Cold-rolled carbon steel offers superior impact resistance and maintains structural integrity under high-stress conditions, which is vital in heavy industries. Stainless steel barrels are favored for food-grade storage and sanitary applications, including the food and beverage, biotechnology, and construction industries, where maximum corrosion resistance and hygiene are priorities.
Metal barrels excel in the food and beverage industry thanks to their resistance to contamination and their ability to maintain product purity. In rugged industrial applications, their durability ensures reliability throughout the supply chain, particularly when exposed to extreme temperatures, impacts, or hazardous handling situations. Metal drums and barrels with United Nations (UN) certification provide compliant storage and transport solutions for dangerous goods, including volatile solvents such as acetone, ethanol, and methanol—these substances can deteriorate plastic, making metal containers preferable.
Specialized metal barrels are engineered for the secure shipment of flammable, toxic, and hazardous waste, and are designed with tight-fitting lids and leak-proof seals to prevent environmental contamination. Barrel integrity is enhanced by rugged exteriors suited for repeated handling and rough transport conditions. The versatility, flexibility, and compliance with international shipping regulations make steel barrels indispensable for transporting a diverse array of chemicals, powders, petroleum products, lubricants, and even pharmaceutical substances.
Industrial plastic barrels, also known as poly drums or blue barrels, are fabricated from advanced polymer materials such as high-density polyethylene (HDPE), polyvinyl chloride (PVC), nylon, and polystyrene. HDPE drums are particularly prized for their high impact strength, chemical resistance, and long life span, making them the most commonly used type in bulk liquid storage and hazardous chemical containment. Plastic barrels can safely store and transport products with a wide range of pH levels, including aggressive acids and bases, which highlights their utility in chemical processing, agricultural, and water treatment sectors.
Plastic barrels are widely chosen for tasks such as dispensing, mixing, filtration, and bulk storage. Available in an assortment of standardized and custom sizes—such as 55-gallon drums, 30-gallon drums, and smaller containers—they are optimized for transporting everything from food and beverage products to hazardous waste. Due to their inert, food-safe composition, plastic barrels are trusted for storing edible oils, grains, vinegar, syrups, juices, pharmaceuticals, and even potable water. They also serve well in industrial settings for containing lubricants, cleaning solutions, and non-corrosive chemicals.
The reusability and recyclability of plastic drums, after thorough cleaning, contribute to sustainability initiatives in supply chain management. Increasingly, used plastic barrels are repurposed for rainwater harvesting, emergency water storage, gardening, and various DIY uses, reflecting their adaptability and eco-friendly value. The wide range of shapes and configurations, including open-head and tight-head designs, offer further versatility for matching specific storage and transportation requirements.
The introduction and widespread adoption of plastic barrels have revolutionized logistics in numerous industries, giving manufacturers and producers flexible solutions tailored to their shipping and storage needs. Their lighter weight compared to metal barrels reduces shipping costs and facilitates easier handling, while their chemical-resistant properties ensure safe long-term containment of caustic or sensitive materials. Whether transporting food products across international borders or safely containing industrial waste, plastic barrels provide a reliable, cost-effective option for modern supply chain and logistics operations.
The manufacturing process of metal barrels, such as steel drums and industrial containers, relies heavily on advanced metal forming techniques designed to ensure strength, leak resistance, and durability. During the initial stage, sheets of carbon steel or stainless steel are processed with an edge grinder to smooth burrs and create uniform edges for safe handling and assembly. These high-strength steel sheets are precision-cut to size and loaded into a bender equipped with a cylindrical mold, carefully forming the barrel’s signature round shape. The process then transitions to automated or semi-automated welding. Spot welding is applied along the seam, followed by seam welding, which creates a continuous, leakproof seal ideal for storing hazardous materials, chemicals, and petroleum products.
Once the main body of the steel drum is fabricated, it undergoes a series of forming operations that refine its physical properties and enhance its load-bearing capabilities. A flanging machine creates rolled edges and rim indentations at both ends of the drum, improving stacking and structural rigidity. Next, the drum is positioned horizontally in a bead expander machine, which forms reinforcing hoops, or rings, around its circumference. These beads serve as stiffeners that prevent bulging or deformation during transportation and storage. Additionally, the use of strategic corrugation along the barrel’s shell increases resistance to external impact, further extending the service life of the steel barrel.
With the drum body completed to industry standards, the next phase involves precision fabrication and assembly of the drum’s end components:
Throughout assembly, strict quality control ensures precision seaming for superior leak protection—critical for barrels used in chemical processing, oil and gas, food storage, and pharmaceuticals. The drum top is fabricated in a parallel manner. Once shaped, it is punched to create standard fill and vent holes, destined for the installation of flanges and closures using specialized die sets. These drum flanges are crucial for compatibility with industrial filling equipment and ensuring secure transport of bulk liquids. After final seam formation, the finished steel barrels may proceed through an automated paint booth, where corrosion-resistant coatings and color identification are applied to distinguish product types or meet regulatory requirements. This step not only enhances durability but also helps customers and regulatory agencies easily identify the drum’s contents and approved uses.
Optional finishing, such as interior lining for food-grade or paint drums, may be added to meet specific user requirements. Through every step, modern metal drum manufacturing combines automated machinery, material science advancements, and rigorous safety standards to deliver high-quality, reliable shipping containers suitable for a diverse range of industries and applications.
Plastic blow molding is the dominant manufacturing method for high-density polyethylene (HDPE) and polypropylene barrels—versatile industrial containers favored for chemical storage, water, pharmaceuticals, and food ingredients. This process involves heating thermoplastic resins until molten and then injecting or extruding them into a barrel-shaped mold. Blow molding creates seamless, leak-resistant containers by expanding the hot plastic against the die wall with compressed air.
Unlike welded steel drums, plastic barrels benefit from a seamless, monolithic construction, eliminating weak points or joints where leaks could occur. Their non-reactive surface makes them ideal for aggressive chemicals, hazardous waste containment, and potable water storage. Common thermoplastics for plastic drum production include thermoplastics such as polyamide, polycarbonate, polystyrene, polyvinyl chloride (PVC), and both low-density and high-density polyethylene, each chosen for temperature tolerance, chemical resistance, and durability. The blow molded barrel’s round shape allows for easy rolling and efficient storage, while the absence of internal crevices prevents microbial growth, maintaining sanitary conditions for food-grade or pharmaceutical applications.
There are three primary blow molding processes used for barrel manufacture: extrusion blow molding, injection blow molding, and injection stretch blow molding. Each method starts by melting plastic resin or pellets and forming a parison, a tube-like piece with an open end. The parison is positioned within the mold cavity and clamped, then inflated with compressed air, causing the polymer to expand until it fits the exact internal geometry of the mold. Once cooled and solidified, the mold is opened, and the seamless drum is ejected. Automated trimming devices or skilled technicians remove flash and protrusions from the drum’s top and bottom, ensuring smooth, uniform surfaces.
Manufacturers often apply additional finishing steps, such as UV stabilization to protect plastic barriers from sunlight degradation, color pigmentation for material identification, and anti-static coatings when used for solvent or flammable chemical storage. Quality control testing—such as drop, leak, and pressure testing—confirms compliance with DOT, UN, and other regulatory standards for shipping and storage. The versatility in size, shape, and material performance makes plastic barrels a top choice for industries that require reliability, corrosion resistance, and cost-effective bulk packaging.
When evaluating metal versus plastic barrel options, consider the specific requirements of your industry—such as chemical compatibility, capacity, stacking strength, regulatory approvals, and intended use environment—to ensure you select the most suitable and compliant container for your business needs. For an in-depth comparison or assistance with product selection, consult with a drum manufacturing expert or an industrial packaging supplier.
The top cover of a closed-head barrel, also known as a tight-head drum, is not detachable. The top and bottom of a plastic drum with a tight head are sealed. Similar to the bottom end, the top side of a closed-head drum forms a durable seal since it is solid and merged with the drum's body. A port known as a bung opening is the sole means to get to a closed-head drum's contents. These tiny gaps are closed off using a bung or another sturdy stopper. Tight-head plastic drums are frequently considered more secure than open-head plastic drums since they are sealed.
Low-viscosity liquids, including water, gasoline, crude oil, and other flammable and liquid combustibles, are ideally suited for closed-head drums. The two-inch bung is designed to accommodate suitable pipe and pumping systems, enabling every drum's secure loading and spill-free filling. Since closed-head drums are frequently used to store liquid hazardous compounds, they must normally be UN-rated, have the proper hazmat labeling, and adhere to strict requirements.
An open-head barrel often called an open-top drum, has a top cover or lid that is completely detachable. Open-head drums can be sealed with a tight cover and fastenings for transport or storage or left open-topped, i.e., without a lid. The top of the container will be used for filling and emptying because it has a single entrance.
They can withstand the demands of shipping because they are built to withstand severe environments and continuous use. Depending on the project's needs, open-head barrels can be used indoors or outdoors and are durable. They are available in various colors and can be readily labeled so that the contents are recognized. Open-head drums are frequently used for shipping or storage since they are highly reliable and well-liked.
Open-head drums can be used to carry liquids, but because of how simple it is to operate the lid and how large the opening is when the top cover is removed, they work best for semi-solid and fluid-like materials (such as sand, dirt, soil, gravel, etc.). Furthermore, an open-head drum can be filled and emptied without requiring special tools or devices, unlike closed-head drums. They can even be manually loaded or unloaded if necessary. Additionally, one of the only viable containers for transporting viscous and thick liquids (such as syrups, certain oils, glues, absorbents, and some solvents) is an open-head drum.
Open-head barrels are utilized because they offer the following advantages:
Taper-sided barrels are lighter and easier to handle than other types of drums. In addition, for simple storage, the tapering sides allow for nesting. Open-headed, taper-sided 55-gallon drums are typically available in several colors. However, blue is the most typical.
Stainless steel drums are becoming increasingly popular to create, ferment, mature, and store wine in the wine business. New designs are created to fit inside wine barrel racks.
Rain barrels are containers that catch rainwater dripping from roofs and downspouts. It is unsafe to consume this drainage because it is non-potable. However, such water is safe to wash automobiles or outside surfaces and water gardens, lawns, and trees.
Drums for collecting rainwater have a straightforward design, are simple to use, and can be placed anywhere. Installing a basic rain barrel utilizes soft rainwater, decreases the need for public utility water, and promotes self-sufficiency. In addition, rain barrels lessen the amount and flow of runoff into the sewer or stormwater systems by collecting and storing rainwater.
Metal barrels can be made from a variety of materials with varying strengths. Therefore, it is useful for storing various materials thanks to these characteristics. It is crucial to know the material that will be kept within to choose the appropriate kind of barrels. Metal drums are widely used for various purposes and are effective for long-term storage and transportation. The following are some of their most common applications:
It's crucial to be sure the barrels one uses can hold the materials one needs because plastic barrels can be created in various grades, strengths, and capacities. In addition, approved polymers are required to store chemicals and other hazardous goods.
Steel barrels are among the most widely used industrial storage choices available today since they offer many fantastic advantages to organizations. Some of these advantages are discussed below.
Steel drums or metal barrels are strong and durable. Most significantly, metal barrels are highly effective at preventing damage to or contamination of the items kept inside. Steel barrels are a great way to store a range of items and work well to hold everything from pharmaceuticals to hazardous trash.
Steel barrels, which continue to be a popular alternative in the food and beverage supply chain, are also a very durable solution for keeping food products. Food can be safeguarded and kept fresh in steel barrels, especially when combined with drum liners. It is crucial to confirm that the steel barrel is certified as "food grade" and that it hasn't previously been used to hold potentially dangerous items before storing food goods.
Steel barrels are excellent for storing items because they are quick to maintain and simple to use. In reality, if a steel drum is kept clean and handled with the proper care and attention, it can last for decades with proper maintenance.
Steel barrels should be cleaned after each usage, but don't worry; they're simple to maintain and clean. Steel barrels can be cleaned with standard cleaning supplies after emptying, depending on what was put within.
Steel barrels may be reused often due to how simple they are to clean and maintain. By ensuring this product has several uses, one can save money on operating expenses while promoting environmental protection. In addition, steel drums can be completely utilized or disassembled and recycled into new barrels at the end of their long lives.
Metal barrels offer protection from physical harm and airborne contaminants, moisture, UV rays, and pests that can be present near the storage location when they are securely sealed. A steel drum can receive additional defense levels by adding waterproof coverings, UV covers, or other protective coatings. These are especially helpful if metal barrels are kept outside.
Metal barrels can be significantly customized to make them even simpler to store, move, and ship across large distances. For instance, many barrels have sturdy handles that make it possible to move them swiftly and without using large gear.
A steel drum can also have various "accessories" attached to it. A drum liner is the most typical accessory. This liner fits within the barrel and prevents contamination between the stored product and the steel.
Metal barrels are made to be used in factories. Hence they are created with the ability to be stacked on top of one another. Metal barrels are big and heavy when filled, but they can be quickly lifted and moved about using industrial equipment like forklifts. They can be conveniently stacked in warehouses for storage or in lorries for shipment. Their design makes it easy to move and transport them, reducing storage space requirements and helping to save time and money.
Lightweight compared to other storage containers like metal drums, plastic barrels are highly portable. Other advantages of plastic barrels are listed below.
Plastic is a very robust and resilient substance. Plastic barrels are made of incredibly strong and resilient materials, which lengthens their lifespan. Plastic barrels resist weathering, temperature changes, and damp, humid, or moist situations. Since plastic is resistant to the impact of ultraviolet radiation, storing drums outside is not an issue. In addition, plastic drums' strong and reliable seal guarantees they won't leak or sweat while being stored or transported. What distinguishes plastic from other sorts of materials is its tenacity and sturdiness.
Importantly, plastic barrels can be customized to carry various substances and are mass-produced in various sizes, making them an excellent value.
The fact that recycled plastic barrels won't end up in a landfill or garbage dump is an additional advantage. Plastic barrels have numerous applications, so there is no longer a need to figure out how to get rid of them, which considerably reduces one component of the rising waste management issue.
The various polymers used to create plastic barrels are inert and resistant to pH levels that are low or high. Therefore, they are the best option for storing and delivering chemicals and other potentially volatile materials because of this property.
Plastic barrels are inexpensive, which is a big factor in why they have grown to be a prized asset. It's the key reason why they gained popularity quickly after being introduced. Plastic is simpler, less expensive, and more useful to create than glass, metal, or any other storage container material. In addition, years of usage with no signs of use, wear, or damage are possible with plastic barrels.
The capacity to preserve and sustain our way of life for future generations is sustainability. Plastic barrels can be reused in countless ways once they have served their specific industrial purpose. Plastic may be easily recycled and repurposed for other purposes, in contrast to the other materials used to make drums. Although this is true for steel and aluminum, the procedures for recycling those materials are extremely difficult and time-consuming. Plastic drums, on the other hand, may be easily shredded and converted into plastic pellets.
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