This article contains information in regards to 55 gallon plastic drums and their use.
You will learn:
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 drums begins with selecting the appropriate high-density polymer, which may include low-density options for specific drum types. The polymers used in drum production start as either resin or pellets, which can be sourced from recycled plastics or freshly produced resin.
Although resins may look similar, their strength and density can differ based on type. Resins are initially viscous substances that become rigid polymers through the curing process. While natural resins exist, modern manufacturing often utilizes synthetic versions that exhibit comparable properties.
The three processes used to produce 55 gallon plastic drums are rotational, injection, and injection blow molding with injection blow molding being the most common and efficient. In the blow molding and injection molding processes, resin pellets are melted before being inserted into the mold cavity. Rotational molding uses a resin powder that is melted in the heated mold.
While resin pellets typically come in clear or white, they can be colored to produce 55-gallon plastic drums in a variety of hues. Common colors include white, yellow, and blue, but manufacturers can provide other colors upon request. During production, the resin pellets are first melted and then shaped into a parison, which is a hollow tube.
To ensure the durability of 55-gallon plastic drums, a UV inhibitor is added to the resin pellets. This additive helps protect the plastic from the damaging effects of sunlight exposure, which can cause degradation over time. Among colors, black offers the best UV protection, while white provides the least.
Blow molding is the predominant method used for manufacturing 55-gallon plastic drums. This technique involves placing a parison into a mold, where it is inflated under pressure to conform to the mold's shape. There are three main types of blow molding: extrusion blow molding, injection blow molding, and injection-stretch blow molding. Each type varies in how it forms the parison, its size, and how it is manipulated within the mold's cavity.
The resin pellets are fed into the hopper manually or automatically where the pellets enter an extruder through the feed barrel. In the extruder, the pellets are heated and moved along to the blow molding die. Heating elements, attached to the outside of the screw drive, heat and melt the pellets so that they can form into the parison for formation in the mold.
The plastic extruder plays a crucial role in the heating phase by ensuring that the pellets are uniformly heated to the same temperature throughout the barrel. This precise heating is vital for preventing defects and inconsistencies in the final 55-gallon plastic drum.
The extruder generates a parison, which is then placed into an open mold that forms the shape of the 55-gallon plastic barrel. In the diagram below, you can see that the parison takes the form of a lengthy, tubular structure, similar to a curtain or drape, suspended between the two parts of the die.
The die sections are pressed together using pneumatic or hydraulic pressure. The ends of the parison are sealed between the die halves, with an opening at the top that lets pressurized air push the parison against the die's walls.
As shown in the diagram below, high-pressure air is introduced into the parison, expanding it to fit the mold's interior. This pressurized air ensures that the parison is evenly spread across the mold’s surface, effectively minimizing the risk of bubbles, imperfections, or defects in the finished product.
The die remains closed until the parison or newly formed drum has cooled. The process of cooling varies depending on the type of polymer being used. To remove the completed drum, the pneumatic or hydraulic motor pulls the die halves apart such that the drum can be easily removed, as can be seen in the diagram.
In contrast to injection and blow molding, rotational molding starts with resin powder, which remains in its solid form until it is placed inside the mold. During the molding process, this powder is heated within the mold.
Rotational molding is designed to create hollow products using steel or aluminum molds with fixed shapes. The process starts with the application of a release agent inside the mold to facilitate the easy removal of the finished drum. In some cases, draft angles are incorporated into the mold to allow for smoother removal without the need for a release agent. The diagram below illustrates the loading of resin powder into the mold.
The mold is closed and rotated on two axes to ensure the even distribution of heated resin powder across its walls. As shown in the diagram below, the mold, depicted by the blue frame, rotates around its axis. This rotation allows the plastic particles to evenly coat the interior surface of the heated mold. The particles melt and fuse in layers until the mold achieves the desired shape and wall thickness. The final thickness, durability, and strength of the product depend on the quantity of powder used in the mold.
This method of rotational molding is one of the many varieties used to produce 55 gallon plastic drums.
Among the various materials used in product manufacturing, plastics are the most versatile and widely utilized, catering to both industrial and domestic applications. The robustness, strength, and adaptability of plastic have established it as a crucial material for a diverse range of products, including plastic drums used for storage, transportation, and shipping.
For drum manufacturing, the plastics used must exhibit exceptional durability and resistance to demanding conditions. This necessitates polymers with specific mechanical properties and characteristics to ensure they can endure rigorous use.
It may seem like all plastics are similar, whether they are used for everyday items like cups and plates or for more robust products like barrels and storage containers. However, there are actually thousands of distinct plastic types, each made from various base chemicals, modifications, and additives. These variations enable the production of a wide array of products, each tailored for specific functional and aesthetic needs.
For the manufacturing of 55 gallon plastic drums, the types of plastics must be exceptionally resilient and strong. The ones that are commonly used include polyvinyl chloride (PVC), high-density polyethylene (HDPE), nylon, and polystyrene. These types of plastics have been used since the 1960s as an alternative to making drums from steel.
Polyvinyl chloride (PVC) is a synthetic resin created through the polymerization of vinyl chloride. As the second most widely produced plastic, PVC is favored in manufacturing due to its rigidity, durability, and flame resistance. These properties make it especially suitable for storing flammable and hazardous materials.
High-Density Polyethylene (HDPE) is a thermoplastic polymer known for its strength, durability, light weight, and chemical resistance. Produced from petroleum through a process called cracking, HDPE is created by exposing petroleum to high temperatures to generate ethylene gas. The ethylene molecules then bond with polymers to form polyethylene. This raw polyethylene is subsequently processed into granules to produce the final polymer material.
Nylon plastic is employed in the production of 55-gallon plastic drums because of its inert nature, low moisture absorption, and chemical resistance. Known as polyamides, these thermoplastics are created by reacting two molecules together using heat and pressure. The resulting material is then formed into sheets, which are subsequently shredded into chips of raw nylon plastic.
Polystyrene is produced through the polymerization of styrene. When combined with other polymers, it gains increased hardness and rigidity, enhancing its suitability for plastic drum manufacturing. Styrene, the key component of polystyrene, is generated by reacting ethylene with benzene in the presence of aluminum chloride, creating ethylbenzene, which is then transformed into styrene. Historically, polystyrene was manufactured using chlorofluorocarbons, but this method has been discontinued due to environmental concerns.
Polystyrene is commonly recognized in everyday items such as cups, containers, and trays. When mixed with other polymers, it becomes more rigid and is utilized in the production of 55-gallon plastic drums.
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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