This article contains everything you will need to know about poly tanks and their use.
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Poly tanks are adaptable containers crafted from plastic, specifically engineered for storing, transporting, and collecting water, liquids, and powdered or granular materials. Made from either polyethylene or polypropylene, these tanks are lightweight, cost-effective, and easily managed, making them perfect for handling substantial volumes of materials.
For decades, storage tanks have been crucial in industrial settings due to their strength, durability, and ease of use. With the introduction of poly tanks, the storage landscape has transformed, offering an impressive blend of reliability and longevity. While metal tanks continue to serve important roles in certain areas, poly tanks increasingly set the standard for contemporary storage needs.
Even though poly tanks are very stable, they require an appropriate foundation for support. Suitable materials for this base include crushed gravel, sand, wood chips, or other firm substances to keep the tank securely in place. Typically, with normal use, poly tanks can have a lifespan reaching up to 20 years, as they are designed with UV stabilizers to prevent sun damage. They need minimal maintenance and can be fitted with self-cleaning systems to clear out debris that may accumulate at the bottom.
Poly tanks come in different categories based on their grade, intended use, and type of polyethylene. Water storage poly tanks are categorized into potable tanks for drinking water and non-potable tanks for other liquids and fluids.
Poly tanks are most commonly positioned vertically, which enhances accessibility. Vertical poly tanks are ideal for storing water, chemicals, and fertilizers due to their ease of use and durability. They are highly versatile, serving various purposes including industrial storage, chemical containment, water reserves, fertilizer holding, and bulk material storage.
Poly tanks are produced through a molding process that creates a robust, impermeable surface resistant to tears, impacts, punctures, and extreme environmental conditions. Food-grade vertical poly tanks are crafted to comply with Food and Drug Administration (FDA) standards for containers used in storing raw food ingredients. These tanks can be equipped with various accessories such as fittings, nozzles, flanges, couplings, insulation, ladder systems, and both internal and external piping, among others.
Vertical poly tanks are designed to be larger and more robust compared to horizontal poly tanks. Their upright configuration provides added strength and durability, making them suitable for agricultural, industrial, and manufacturing uses. These tanks are capable of holding a diverse array of fluids, liquids, and chemicals, including different types of acids.
Horizontal poly tanks are more compact and easier to move than their vertical counterparts. They can be transported using forklifts, trucks, tractors, or trailers. Sometimes, these tanks are fixed permanently on the bed of a truck or trailer. Their low profile facilitates easy loading and filling while ensuring minimal disruption to the vehicle’s center of gravity.
Horizontal poly tanks differ from vertical tanks by having built-in legs that provide stability and make it easier to move and reposition them. This design flexibility increases their range of potential uses. These tanks often feature a translucent construction for monitoring liquid levels and include calibration markings. Their low profile is particularly advantageous in areas with limited space, contributing to their widespread use.
Similar to vertical poly tanks, horizontal tanks are designed for easy filling and loading, typically featuring an access hatch at the top center. To maintain structural integrity, their length is generally no more than six times their diameter, which influences their size. Standard features of horizontal tanks include pressure vacuum vents, gauge hatches, and sample wells. In addition to the common cylindrical shape, horizontal poly tanks are also available in square or rectangular cross-sections.
Underground poly tanks, often called cistern tanks when used for potable water storage, can hold up to 20,000 gallons. These robust tanks are designed to be waterproof and withstand soil conditions. After installation, risers are added to provide access to the tank.
Underground poly tanks must be specially molded and designed to suit their intended use. They are often employed to conserve land space or in locations where above-ground tanks are not allowed. Additionally, burying a poly tank can help shield it from sun exposure. Risers are installed on these tanks and linked to a pump and piping system to allow access to the tank’s contents.
Installing an underground poly tank involves meticulous preparation to ensure stability and proper positioning. Beyond simply digging the hole, the bottom must be filled with granular material to facilitate drainage and prevent moisture buildup beneath the tank. Suitable materials include pebbles, gravel, or coarse sand. It’s crucial that the tank is set level, even if the site has a slope.
Underground poly tanks come in various designs, including both horizontal and vertical configurations, with vertical cylindrical tanks being particularly common. The choice of tank size depends on the type of material being stored, its intended location, and specific application needs. For tanks used to store potable water, strict regulations and safety standards must be adhered to ensure user safety.
Silo poly tanks differ from vertical and horizontal tanks as they feature a conical end designed for dispensing contents. They have specific requirements that may not apply to other tank types due to their specialized use, which often includes storing animal feed, grain, and various agricultural products. Given the weight of the stored materials, silo poly tanks require a robust framework to provide adequate support and stability.
For safe and convenient access, the clearance beneath a silo poly tank is precisely measured. These tanks offer substantial capacity, up to 10,000 liters (22,000 pounds), and feature appropriately sized fittings to accommodate their contents. Their design provides a minimal footprint, with most of the structure elevated on a supporting frame. A large hatch at the top of the silo poly tank facilitates easy filling and loading.
Chemical storage plays a vital role in many industries and demands stringent safety measures for both workers and the environment. Chemical poly tanks are increasingly used to manage and contain hazardous waste. Their popularity has risen due to their robustness, corrosion resistance, and affordability. The size of these tanks depends on the volume of chemical waste they need to handle, and they are constructed from durable materials that can endure harsh chemicals and environmental conditions.
Compliance with regulations is crucial for the use of poly chemical tanks in chemical storage. The Environmental Protection Agency (EPA) frequently updates its standards to ensure the safe storage of hazardous chemicals. Manufacturers of chemical poly tanks follow these EPA guidelines closely and offer certification to confirm that their products meet these safety requirements.
While investing in a chemical poly tank is a smart choice, maintaining its integrity presents ongoing challenges. Proper care involves careful discharging, cleaning, and regular upkeep of the tank. The discharge process is particularly crucial and requires specific procedures to ensure environmental safety. Like other poly tanks, chemical poly tanks are equipped with a flange outlet, which is integral to their design and essential for their functionality.
Most chemical poly tanks are vertical because they offer greater capacity. Their one-piece construction, typical of molded poly tanks, improves sealing, protects contents, and helps prevent leaks, impact damage, and environmental harm. A distinctive feature of chemical poly tanks is their double-wall construction, which enhances strength and durability.
Poly septic tanks are designed for underground use and are built to resist the impact of soil chemicals and sewage gases. Like other poly tanks, they feature a single-unit construction that ensures a tight seal. These tanks often come pre-plumbed from the manufacturer, which helps reduce the initial installation cost.
One significant benefit of poly septic tanks compared to concrete ones is their lighter weight, which simplifies the installation process. This often only requires one piece of heavy-duty equipment, thereby reducing overall costs. Moreover, poly septic tanks offer greater flexibility and can be installed in a wider range of locations than concrete tanks, making them suitable for areas where concrete tanks might not be ideal.
Poly septic tanks are typically more affordable than concrete septic tanks while offering similar longevity. This cost-effectiveness is enhanced as the initial investment can be spread over many years. Delivered pre-plumbed and ready for installation, poly septic tanks are placed underground on a stable bed of material to prevent moisture buildup. Additionally, if expansions or modifications are needed at the property, a poly septic tank can be easily relocated with minimal effort compared to concrete options.
RV poly tanks are a versatile category of tanks commonly used in boats, for ballast, graywater, and various freshwater applications. Like most poly tanks, RV poly tanks feature a seamless design to ensure leak prevention and minimize contamination risks. They are available in numerous sizes to accommodate the diverse range of their uses.
RV poly tanks typically come in rectangular shapes and sizes, with some designs featuring multiple rectangular sections molded together as a single unit. These tanks are linked to pumps that deliver freshwater to various fixtures like toilets, bathtubs, showers, and sinks. The setup is akin to a residential plumbing system, with the main difference being that the water source is a tank rather than a municipal supply.
RV poly water tanks are built to meet the same specifications as those used for municipal water supplies, as set by the FDA. These tanks are designed and produced in accordance with FDA and EPA standards, ensuring they are suitable for storing fluids intended for human consumption.
Rectangular poly tanks come in various designs and are known for their versatility. Their distinctive construction allows them to be used in a broad array of applications and settings. While their uses are similar to those of cylindrical horizontal and vertical tanks, rectangular poly tanks are particularly favored for water storage due to their customizable shapes and configurations.
Rectangular poly tanks offer a unique advantage with their open-top design, available with or without a lid, which is not feasible with other poly tank shapes. These tanks are utilized in recirculating systems, research, material transport, and food and beverage production. Unlike cylindrical tanks, rectangular poly tanks can be stacked, making them ideal for spaces with limited room. Their design provides stability and allows them to stand independently. The flat, sturdy base of rectangular poly tanks allows for flexible placement, while their durable poly construction protects the stored contents.
Poly water tanks, also known as polyethylene tanks, plastic water tanks, or water storage tanks, have long been used by farmers, rural communities, and remote areas for storing well water and capturing rainwater. These molded tanks come in a variety of sizes, diameters, capacities, and heights. Poly water tanks are available in both horizontal and vertical orientations, with larger models capable of holding over 2,000 gallons (11,356.24 liters) and reaching up to 50,000 gallons (189,270.59 liters).
Poly water tanks are typically available in colors such as green or black, with some manufacturers also offering dark brown or mocha options. This limited color range reflects their primary use in remote or challenging locations where functionality takes precedence over aesthetic variety.
A key aspect of poly water tank design is their specific gravity rating, which indicates the tank's capacity to hold water relative to its weight per unit volume. This rating reflects how well the tank can withstand hydrostatic pressure from the water it holds. For reference, the specific gravity of water is 1.0, as one gallon of water weighs 8.334 lbs. (3.78 kg).
The specific gravity of poly water tanks is primarily influenced by their wall thickness and overall design. Rural consumers often select tanks with thicker walls and designs tailored to their installation conditions. In remote areas, the failure or rupture of a water storage tank can lead to severe and damaging consequences.
Poly water tanks are popular among rural communities and farmers not only for their durability but also for their resilience to temperature extremes. These tanks can handle temperature fluctuations from -40°F to 100°F (-40°C to 38°C) without issues. However, prolonged exposure to temperatures above 100°F may still pose challenges for poly water storage tanks.
In rural areas, one of the main concerns with long-term water storage is the potential for bacterial and algae growth, a common issue with other types of storage tanks that necessitates frequent inspection and cleaning. Poly water tanks, however, are resistant to decay and rust and do not come into contact with the ground, reducing the risk of mold or algae formation. To further prevent algae growth, using an algicide can be an effective measure.
Choosing the size of a poly water tank depends on various factors. Larger tanks, ranging from 10,000 to 50,000 gallons, require less frequent filling, which can reduce labor, time, and transportation costs. However, the increased weight of these larger tanks can pose challenges for transport by trucks and trailers.
Benefits of Larger Poly Water Tanks
Smaller Poly Water Tank Advantages
Underground poly water tanks are often used when there isn't enough space available above ground for a water storage tank. Like other poly water tanks, these underground versions are rotation molded to ensure a complete seal. Installing a poly water tank underground shields it from sunlight, which can otherwise damage the tank and promote microbiological growth.
Underground poly tanks are certified for potable water and typically feature pumps and piping systems for easy access. They are buried deep enough to guard against freezing temperatures. While above-ground water tanks can store hundreds of gallons, underground versions are also available in sizes that accommodate hundreds to thousands of gallons, buried at depths ranging from four to ten feet (1.22 m to 3 m).
The poly tanks discussed above represent just a fraction of the various options offered by manufacturers. They do not cover the wide range of custom tanks made for specific and unique applications. Manufacturers collaborate closely with their clients to design tanks that precisely meet their needs, including the necessary fittings, connections, plumbing, and other accessories tailored to client specifications.
One of the key attributes of poly tanks is their seamless, solid walls, which ensure leak prevention and impact resistance. Unlike standard plastic products, which may use various molds that are either permanent or temporary with melted resin poured into them, poly tanks require specialized manufacturing processes. These techniques are designed to create large containers with thicker, more resilient walls to meet the demands of their size and durability.
Rotational molding and blow molding are the primary techniques employed in the production of poly tanks, as both methods utilize large molds. Poly tanks are made from two main polymers: polyethylene and polypropylene, both of which offer robust and durable properties essential for manufacturing these tanks.
Rotational molding, or roto molding, is commonly used to manufacture large poly tanks with substantial capacities. This process involves three main steps: heating the mold while it rotates. The rotation ensures that the plastic resin is distributed uniformly across the mold's surface. During the process, the resin is added to the mold in granular form and melts as the mold is heated.
At the workstation, which may be elevated for convenient access, a worker adds a precisely measured amount of resin into the mold. This resin, which is dry, fine, and consistent, ensures smooth flow and prevents bubble formation in the poly tank's walls. The measured amount of resin directly affects the thickness and strength of the tank's walls, ensuring the final product meets the required specifications.
To facilitate the easy removal of the finished poly tank, a release agent is applied to the inside of the mold. This mold, typically crafted from cast metal, is designed with the exact shape and dimensions of the final poly tank to be produced.
Once the resin-filled mold is securely sealed, it is transferred to a furnace where it will be heated. The mold then starts rotating on multiple axes as it exits the workstation, ensuring that the resin is evenly distributed across the mold's interior. The wall thickness is determined by the mold's rotation speed, with a specific ratio of rotations per minute (RPM) on the horizontal axis compared to the vertical axis. This rotational ratio is carefully adjusted based on the poly tank's shape, as different shapes like spheres or cubes require different ratios for optimal results.
Heating time for poly tanks is adjusted based on the specific shape and type of tank being produced. Accurate control of heating time is crucial for ensuring the final product's quality, as both overheating and underheating can lead to defects in the poly tank.
During the cooling phase, the poly tank solidifies into its final shape. As the resin hardens on the mold's walls, it's essential to apply cooling air gradually to prevent rapid cooling, which could distort the tank. For some designs, water may be sprayed to expedite the cooling process, but this must be carefully managed to ensure it doesn’t compromise the tank’s properties or dimensions.
Similar to the heating process, the cooling period is carefully regulated to match the size and type of the poly tank. Proper cooling rates are crucial, as either too rapid or too gradual cooling can compromise the structural integrity of the tank, affecting its quality.
Once the poly tank has cooled sufficiently, it is moved back to the workstation for removal from the mold. An air ejection system aids in this process by pushing the tank out of the mold. After demolding, the tank undergoes an inspection to check for wall uniformity, bubbles, distortions, or other defects. Being a single-piece mold, poly tanks do not require further division. Additional processing may involve cutting openings for flanges, fittings, connections, lids, or other custom modifications as needed.
Blow molding is another method used for creating poly tanks and can manufacture tanks of various sizes, including those much larger than those made by rotational molding. Like rotational molding, blow molding also utilizes molds, which can range from small containers like trash cans to large tanks designed for underground use. This technique is commonly employed for producing clear plastic bottles and containers in large quantities.
Creating large poly tanks involves a more extended production process but allows for the manufacture of tanks with high precision. Blow molding, like rotational molding, consists of three main stages, but it also includes an extra step where the resin is melted and heated prior to being injected into the mold.
In blow molding, the resin undergoes a heating and melting phase before being introduced into the mold. This part of the process is comparable to other molding techniques and utilizes an extruder, which includes a hopper, a screw, heaters, a barrel, and a nozzle. Resin is gradually fed into the barrel from the hopper. As the screw rotates, it pushes the resin along the barrel, where it is heated until it becomes molten and ready for molding.
During the blow molding process, the extrusion phase creates a flexible, inflated preform known as the parison. This parison, shaped like a closed-end tube and resembling a large cylindrical balloon, is produced by the nozzle at the end of the extruder. As the parison is formed, its wall thickness is carefully controlled to ensure that when it expands within the mold, the resulting poly tank will have uniform and smooth walls.
The extrusion head plays a crucial role in managing the wall thickness of the poly tank through its conical design. By adjusting the position of the mandrel and the conical outer ring of the extrusion head, the thickness of the parison can be precisely controlled. This allows for the final poly tank to achieve the desired wall thickness, ensuring uniformity in the finished product.
After the parison is shaped and ready, it is inserted into the die, which consists of two halves that are securely clamped together. Ensuring a tight seal of the die is crucial to avoid any gaps and to guarantee the even distribution of the parison throughout the mold. Proper spreading of the parison is vital for achieving uniform wall thickness in the final poly tank.
Blow molding dies come in a vast range of sizes, allowing for the production of poly tanks ranging from just a few gallons to several thousand gallons. While smaller dies are relatively easy to handle, larger dies resemble heavy-duty forging presses due to their substantial size and complexity.
In the blow molding process, pressurized air is introduced into the parison, causing it to expand swiftly and conform to the mold's walls. To ensure uniform wall thickness, the air must be applied evenly. Similar to the heating phase in rotational molding, the air pressure in blow molding is meticulously regulated to prevent excessive stretching of the parison.
In the case of square or rectangular poly tanks, air is often distributed through multiple orifices to achieve consistent airflow, as the angles and corners of these molds can be challenging to reach. By using several air channels, the parison is effectively pushed into the corners and edges of the tank, ensuring a thorough and even fill.
The final stage in the blow molding process involves cooling and solidifying the poly tank. Unlike rotational molding, where the entire mold is heated, blow molding primarily heats only the parison. Consequently, the cooling phase for blow molding is generally shorter, although it remains the most time-consuming part of the procedure. Cooling starts as soon as the air is applied and continues throughout the molding process.
During the cooling phase of blow molding, the heat from the parison is conducted to the interior surface of the mold. One challenge in this stage is managing the residual heat trapped inside the poly tank. To address this, internal cooling systems are employed, ensuring a safe and effective method to expedite the cooling process.
Similar to roto molding molds, blow molding molds consist of two halves that separate once the poly tank has cooled adequately. After removal from the mold, the poly tank undergoes a thorough inspection to check for any deformations or leaks, a crucial step particularly for large tanks that hold hundreds or thousands of gallons.
Poly tanks are made from resins derived from petroleum, commonly referred to as polymers or plastics. These terms encompass a broad spectrum of plastic materials with diverse grades, types, strengths, and chemical compositions. Each type of plastic is chosen for its specific properties, making it suitable for different applications in plastic manufacturing.
Poly tanks are primarily made from two widely used polymers: polyethylene and polypropylene. These versatile materials are employed globally in a variety of products, including clothing hangers, beverage bottles, and durable equipment casings. Their robustness and adaptability make them ideal for manufacturing poly tanks and numerous other applications.
Polyethylene, often abbreviated as PE, polythene, or polyethene, is produced through the polymerization of ethylene (C2H4), an organic hydrocarbon. This process involves adding titanium chloride and high molecular weight nonpolar saturated hydrocarbons. The result is a crystalline plastic with properties similar to paraffin. Polyethylene's molecular structure, which lacks cross-linking, contributes to its high density and chemical stability.
Polyethylene comes in various forms, including low density (LDPE), linear low density (LLDPE), linear medium density (LMDPE), high density (HDPE), ultra high molecular weight (UHMWPE), and cross-linked (PEX). While all these types have their uses in manufacturing, poly tanks are primarily made from PEX, LMDPE, and HDPE. These specific types are chosen for their superior mechanical strength, durability, and resistance to environmental conditions.
Among the various materials used for manufacturing poly tanks, polypropylene—also known as propene, PP, or propylene—is particularly versatile. This plastic can be utilized in a range of applications, including textiles, packaging, and poly tanks. It is produced through the polymerization of the propene monomer using either the Ziegler-Natta process or metallocene catalysis. Polypropylene features a crystalline structure that provides it with flexibility, durability, chemical resistance, and the ability to withstand temperature fluctuations. It is part of the olefin family of double-bonded hydrocarbons. During polymerization, the propene molecules undergo bond rearrangement to form the polypropylene polymer chain.
Polypropylene stands out for its exceptional chemical resistance, ability to endure temperature fluctuations, and high level of purity. Its robust strength and durability make it a suitable choice for producing containers, including poly tanks.
Polyvinyl chloride, or PVC, comes in flexible and rigid forms, depending on the additives used. Renowned for its remarkable mechanical properties, PVC is well-suited for demanding environments requiring durable materials. Its strength rivals that of many metals, which is why it's commonly used in plumbing applications. PVC is primarily composed of chlorine, derived from salt, combined with carbon and hydrogen. It is manufactured from vinyl chloride monomer, which is produced through the chlorination of ethylene and pyrolysis, followed by polymerization to create PVC.
PVC, a thermoplastic, becomes pliable when heated, allowing it to be molded into poly tanks. The rigid variant of PVC is utilized in the production of these tanks, offering a high-density material that is both impact-resistant and chemically durable.
Poly tanks have long been utilized for water storage and the transportation of chemicals like pesticides and fertilizers. Their popularity in agriculture stems from their durability, strength, and ease of movement. The lightweight nature of poly tanks allows for flexible placement in various locations, reducing the risk of cracking or leaking.
Poly tanks are often preferred over metal tanks primarily because of their lower cost. This affordability is attributed to the inexpensive raw materials required for their production, as well as the more efficient manufacturing processes involved. Consequently, poly tanks offer a cost-effective alternative to metal tanks.
Poly tanks, being lightweight, can be effortlessly placed without the need for specialized support. Installing underground poly tanks is simpler compared to concrete alternatives. Their sturdy construction ensures leak prevention, and the poly material remains unaffected by soil chemicals.
Another advantage of poly tanks is their ease of handling due to their lightweight nature. They can be moved or repositioned without the need for heavy machinery or specialized tools. This flexibility is particularly useful for companies undergoing expansion or renovations, as poly tanks can be emptied, lifted, and relocated as needed to adapt to new requirements.
Poly tanks come in a vast array of sizes, colors, shapes, and designs, making them suitable for a wide range of industrial applications and spatial requirements. Additionally, manufacturers collaborate with clients to create customized poly tanks tailored to specific and unique needs, ensuring versatility and adaptability for various situations.
The variety of poly tank designs and colors allows them to be seamlessly integrated into the architectural aesthetics of a building, a flexibility not typically found with other types of storage tanks. Often, architects incorporate poly tanks into their designs, taking advantage of their adaptability to meet specific architectural needs.
Poly tanks are renowned for their robust durability, making them ideal for challenging environments where they store water and chemicals. Unlike some metals, poly tanks resist rust and are immune to varying weather conditions. They are designed to withstand extensive use over many years with minimal maintenance and do not require specialized cleaning procedures.
Poly tanks are certified by the FDA and EPA for storing and transporting potable water. Their construction materials are highly hygienic and sanitary, making them a popular choice in the food and pharmaceutical sectors for their reliability and cleanliness.
Given the diverse range of liquids stored in poly tanks, regulatory bodies such as the FDA, EPA, NSF, and ANSI have established guidelines and standards for their production. These regulations primarily focus on the safe storage of potable water and food products, ensuring that any fluids or liquids in contact with humans meet strict safety and hygiene requirements.
Given the extensive use of poly tanks for potable water storage and transportation, various regulatory agencies have set specific requirements. The polyethylene used in these tanks must be inert, ensuring it does not leach chemicals or react with the water. Manufacturers must hold certifications from the Environmental Protection Agency (EPA), the Food and Drug Administration (FDA), the Code of Federal Regulations (CFR), the National Sanitation Foundation (NSF), and the American National Standards Institute (ANSI), which are typically indicated on their products.
Poly tanks are required to be built to endure the pressure exerted by the stored water. This includes specifications for wall thickness and uniformity, which are assessed and verified during production. While manufacturers may use various types of resins, they all ensure that the resins comply with relevant regulatory and organizational standards.
Title 21 of the FDA and CFR outlines the standards for poly tanks used in food and beverage storage and processing. This section details the permissible resins, additives, and the construction specifications for these tanks. Poly tanks are preferred for their single-piece, seamless design, which enhances safety and dependability compared to other tank types.
Section CFT 1250.82 of Title 21 specifies the standards for poly tanks intended for potable water. These regulations cover aspects such as drainage, overflow management, venting, and techniques for gauging water depth. A key focus of these standards is to prevent any potential backflow that might lead to contamination of the stored drinking water.
Regulations governing poly tanks vary across different sectors, with a particular focus on those used in industrial settings. The primary concern is safety, ensuring that water remains uncontaminated and chemicals are securely contained to prevent leaks. Different organizations establish detailed guidelines for both above-ground and below-ground installations, with the latter requiring more stringent and rigorous standards.
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