Switching to bulk bags can significantly reduce risks for your team when used correctly. Ensuring safety and efficiency in operations requires that both the bulk bag and the filling equipment are designed to handle the demands of your environment. In a recent article, we break down best practices for handling dry material and, in this article, we will dig deeper into the essential guidelines for safe bulk bag handling, including pre-inspection procedures, weight rating, correct use of liners, sealing and dust containment, and special considerations for automated systems, and more!
Handling Guidelines
Bulk bags, or FIBCs, and bulk bag fillers are essential in various industries, from agriculture to pharmaceuticals. According to the Flexible Intermediate Bulk Container Association (FIBCA), when choosing a bag, it’s crucial to select one designed for your specific filling and emptying processes. The bag’s fabric, loops, and liners must be compatible with the material being handled and the equipment used.
Key Guidelines:
Material Compatibility: Ensure the bag’s fabric is suitable for the specific material it will contain. For example, when handling materials such as chemicals or pharmaceuticals, using a bulk bag with an inner liner is crucial to prevent contamination and ensure safe handling. The liner provides an additional barrier that helps protect both the product and the environment from exposure.
Weight and Capacity Requirements: Verify that the bag’s Safe Working Load (SWL) and capacity ratings match the operational needs. Weight is the critical measurement, not volume, because some materials have a greater bulk density than others. For example, a bulk bag filled with lead powder will weigh much more than the same volume of plastic pellets. Thus, it’s essential to focus on the weight rating of the bag to avoid overloading and ensure safety.
Handling Guidelines: Always follow the manufacturer’s specific instructions for lifting, filling, and discharging the bag. On all FIBC bags, there should be a “bag tag” provided by the manufacturer outlining guidelines for proper handling procedures.
Check out this article on unlocking operational efficiency with FIBC bags to learn more about bulk bags.
Pre-Inspection
A thorough inspection of both the bag and the filling equipment is crucial before beginning the filling process. This important step helps prevent accidents and ensures that the filling process runs smoothly, and should be a part of your operations procedures.
Inspection Checklist:
Bag Inspection:
- Loops: Check for fraying or damage.
- Body: Inspect for tears, punctures, or weakened fabric.
- Spout and Bottom: Ensure these parts are intact and free of defects. Specifically, check to see if the discharge spout is tied off prior to filling.
Filling Equipment Inspection:
- Spout Seal: Confirm it forms a tight seal with the bag’s filling spout.
- Scale: Verify its accuracy and In proper calibration.
- Height Adjustment: Ensure it can be adjusted to accommodate different bag sizes.
- Attachment Components: Check all hooks, clamps, and support structures for integrity.
Bag Weight Rating and Capacity Training
Understanding and adhering to the weight ratings and capacity limits of bulk bags is critical for safe operations and a requirement of OSHA, DOT, and ISO. Overloading or overfilling can compromise the bag’s structural integrity, leading to potential safety hazards. It’s also important that you train operators on the capacity limits of the bulk bags that are being filled and keep the information somewhere that can be easily referenced by your team.
Avoid Overfilling/Overloading:
Safe Working Load (SWL): Never exceed the SWL marked on the bag. For instance, a bag rated at 2,000 pounds should not be loaded beyond this limit.
Stability Maintenance: Fill bags only to a level where they remain stable. Avoid overfilling that affects the height-to-width ratio.
Scale-Controlled Fillers: Use these to ensure each bag is filled precisely to the required weight, enhancing safety and efficiency.
Choosing the Right Bulk Bag
There are thousands of bulk bags available in the market today. They come in different sizes, capacities, fill options, discharge options, and special features such as static control, odor control, and UV inhibiting properties. Working with a knowledgeable bulk bag supplier to find the right configuration for your application is important.
How to Read a Bag Tag
Understanding the symbols and information on a manufacturer’s bag tag is crucial for ensuring the safe and effective use of bulk bags. Here’s a guide to the common symbols and terms you may find:
Symbols and Terms:
- Safe Working Load (SWL): Indicates the maximum weight the bag can safely hold. This is a critical measurement and should never be exceeded.
- Safety Factor: Often shown as a ratio (e.g., 5:1 or 6:1), this indicates the bag’s strength
relative to its SWL. A 5:1 safety factor means the bag has been tested to hold five times its SWL without failing. - Capacity: The volume the bag can hold, typically measured in cubic meters (m³) or liters (L). Remember that weight is more critical than volume for safety.
- Material Type: Specifies the material used for the bag, such as polypropylene. This helps determine the bag’s suitability for different types of contents.
- Liner Requirement: Indicates whether a liner is needed and the type of liner recommended.
- Handling Instructions: Icons or text showing proper lifting points (usually the bag’s loops) and methods for safe handling.
- FIBC Class: Indicates the type of use for the bag, such as single trip (one-time use) or multi-trip (reusable).
- ISO 9001 Certified: Shows that the bag manufacturer adheres to internationa
l standards for quality management systems. - Recycling Symbols: Information on the recyclability of the bag materials, important for environmental considerations.
The image to the right is an example of what a FormPak bag tag looks like.
Ensuring Proper Support
If filled correctly, bulk bags are a great solution for material storage because they can be stacked. Proper support during filling is essential to prevent filled bags from leaning or collapsing, which can pose significant safety hazards. The bag must be supported to maintain its shape and ensure even filling.
The image to the left shows leaning bags as a result of improper filling practices. When stacked, leaning bags post serious risk to operators.
Best Practices for Support:
Adjustable Supports: Ensure the filling system can support the bag whether a pallet is used or not. Adjustable supports can accommodate various bag sizes and weights.
Filling Height: When filling, the bag should be slightly suspended above the pallet to ensure the corners of the bag are filled and the fabric can stretch properly. The general rule is to keep the corners of the bag 3”-4” above the pallet. If it’s too low or too high, you risk uneven filling.
Correct Use of Liners
Liners are crucial for maintaining the integrity of the material inside the bag, especially when dealing with fine powders or materials that require additional containment. Liners are also beneficial for making bags more durable, protecting them from abrasive materials and extending their life.
Common Liner Options and Usage:
Standard Tubular and Inserted Poly Liners: Suitable for general applications where a basic liner is sufficient.
Formed and Foilized Liners: Provide enhanced protection against moisture and contaminants.
Baffled, Tied-In, Sewn-In, and Conductive Liners: Designed for specific needs, such as maintaining bag shape, preventing contamination, and dissipating static electricity.
Securing Your Liners
Pre-inflation: Pre-inflate liners before filling to ensure they fit properly and reduce the risk of punctures. Different methods for pre-inflation include using compressed air venturi, expanders, or positive displacement blowers for efficient pre-inflation.
Check placement: Securing the liner correctly during filling and discharge is essential to prevent spills and contamination. Ensure the liner extends past the fill spout or duffle and is tied off properly.
Sealing and Dust Containment
Effective sealing and dust containment are critical to protect operators from dust exposure during filling. Proper sealing also ensures the integrity of the material inside the bag and leads to less waste.
Best Practices for Sealing:
Use Proper Sealing Devices: Use proper devices such as clamps or purpose-built sealing mechanisms instead of bungee cords, which are more likely to fail.
Dust-Tight Connections: Equip fillers with dust-tight connections to prevent dust from escaping during filling.
Dust Collection Systems: Incorporate efficient dust collection systems to capture any residual dust.
For more on industrial hygiene, check our article on industrial hygiene and safety assessment.
Special Considerations for Automation
Automated filling systems can enhance efficiency and ergonomics but require careful operation to avoid injuries. Operators must be trained to handle automated systems safely.
Automated filling systems may include automatic release of the bag spout and lift loops, and drive the full bag from the machine via roller conveyors. While these systems offer improved ergonomics and allow the operator to be outside of the bag removal and forklift traffic, they require some important behavior and awareness to avoid injury. Operators must ensure that they do not have fingers, arms or other appendages near automatically moving mechanical systems. They must also stay clear of and never stand on powered rollers, belts or other conveying devices. These systems should include proper E-Stops, lockouts, disconnects, interlocks and even buzzer or light warnings when operating in automatic mode.
Safety Measures for Checklist for Automation:
- E-Stops and Lockouts: Ensure the system includes emergency stops, lockout mechanisms, and disconnects.
- Interlocks: Use interlocks to prevent the system from operating when safety guards are open or when an unsafe condition is detected.
- Warnings: Implement visual and auditory warnings (buzzers, lights) to alert operators during automatic operations.
- Operator Training: Train operators to avoid placing fingers, arms, or other appendages near moving parts and to stay clear of powered rollers, belts, and other conveying devices.
Optimizing your bulk bag filling operations not only ensures safety but also enhances efficiency. Proper selection, inspection, support, and sealing practices are key to maintaining a safe and productive environment. For more information and assistance, check out this article on bulk bag fill rate and explore our range of products designed to meet your specific needs.
For further inquiries, contact us at FormPak today. We are here to help you achieve the highest standards in bulk bag filling and handling.
