Bulk bags, also known as FIBCs (Flexible Intermediate Bulk Containers), have transformed material handling, providing a safer and more efficient alternative to traditional methods like the manual handling of 50lb bags. Bulk bags and their respective handling equipment are a significantly more ergonomic option that protects your team from the long-term effects of heavy lifting. However, they don’t come without their potential risks.
To help you implement dry bulk material handling systems in your operation and unlock a greater level of efficiency, it’s important to understand the proper use of bulk bag unloaders and safety procedures. This comprehensive guide covers everything you need to know about unloader safety. If you’re interested in learning more about loader safety, check out our Bulk Bag Filler Safety Guide
Download the FIBCA Safety Guidelines.
Bulk Bag Unloading Safety Hazards
While injuries related to bulk bags are less frequent compared to handling small bags, boxes, drums, and Gaylords, they can occur if proper equipment or procedures are not utilized. The most common injuries include crushing of the hand or arm, often occurring when an operator reaches under a non-supported bag that is either lowered incorrectly or fails and falls. The chart below gives a side-by-side comparison of the risks associated with bulk bag material unloaders (automated equipment) versus manual unloading of small bags, boxes, drums, or Gaylord cartons.
| Injury risks | Bulk bag unloaders | Manual unloading of small bags, boxes, drums, and Gaylords |
| Crushing injury | X
(very uncommon) |
X |
| Muscle strain | X | |
| Chronic conditions from repetitive heavy lifting | X | |
| Chronic illness from dust inhalation | X |
How to Maximize Safety in Your Operation
Bulk bag unloader safety boils down to two factors: having the right equipment that’s certified for your use case and proper use of the equipment.
Ensure You Have the Right Equipment
At FormPak, we design heavy-duty super sack handling equipment made with a robust design and optimal components for safe operations. Here are the features we recommend for reducing the risk of accidents while unloading FIBCs.
Always Use Certified Equipment
This is important no matter what type of operation you have. Uncertified devices aren’t held to the same rigorous standards as certified equipment, which means they don’t go through as much testing and they aren’t guaranteed to perform in demanding industrial operations. Using uncertified lifting devices can lead to catastrophic failures. Ensuring all lifting devices are tested and certified can prevent such costly incidents.
For more details on certified lifting devices, read our article: Is Your Bulk Bag Lifting Device Tested & Certified?
Have Proper Bag Support
One of the most common unloading accidents occurs when a suspended bag falls or crushes the operator’s hands or arms as they attempt to untie the spout. The best preventive measure is to rest the bag on a sturdy support structure with an opening in the bottom. The operator can then safely reach their hand under the support to open the bag with reduced risk of injury. This is not only the industry standard but also required by OSHA. If audited or an injury occurs, OSHA may issue a violation and fine.
There are many unloader configurations that provide ample support, which include bag-shaped receiver hoppers, paddles or plates on four sides, or a structural steel tube that the bag can be lowered into.
FormPak unloaders feature optional iris valves and access doors, which let the operator open the bag without having to step under it. The iris valve prevents material from exiting the bag while the operator unties the spout. An access door guards against exposure to the product as the bag discharges.
Comparing Unloader Styles
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Image credits: Bulkinside |
| Bag Shaker with Bag-Shaped Receiver | Paddle Massager |
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Avoid Dangerous Pinch Points
Bulk bag unloaders and their ancillary components have many pinch points which could result in severe injuries to the operator’s hands or arms. One common pinch point is found with bag massaging systems, which use hinged paddles or bars to promote the flow of material. These should be guarded to prevent operators from reaching into them.
As a safer alternative to hinged paddles or bars, FormPak unloaders feature a bag shaker with a heavy duty gyrator and rubber isolators to shake the support pan. This vibratory, re-fluidizer design ensures product flow without the pinch points of paddle style machines. Units that feature a piercing device should come with a safety gate that protects the operator from exposure during use.
Dissipate Static Charge to Prevent Fire
When handling powdered materials, static charges can accumulate as the material is transferred or moved, creating potential fire hazards and increasing the risk of dust explosions.
Static is common in unloading operations and must be mitigated, depending on the potential charge. The Flexible Intermediate Bulk Container Association notes that bags must be appropriate for the environments in which they are used. Bags and unloading equipment must also be properly grounded.
Type C and Type D Bags
One way to address this problem is to choose ground-able bags which need to be attached to a ground point. Known as Type C bags, they have a carbon-infused grid within the fabric to direct any charges to that grounding point. Any equipment used with Type C bags must include a grounding strap with a positive attachment device or clip. This can often be tied to a continuity device that locks out the access door to prevent use when a grounding system is not present.
Type D bags, on the other hand, are made of a special static dissipative fabric. These bags do not require grounding. Instead, they are kept below the ignition threshold by sloughing or losing static charge at a constant rate.
It’s essential to be familiar with the types of bags being discharged as well as proper grounding requirements.
Reducing Inhalable Particulate Matter
Bulk bags are often used to store, transport, and unload dusty or aerated materials.
Unloading systems must be designed to minimize the operator’s exposure to these substances. This can include mechanical or pneumatic spout sealing, in which the bag spout is sealed prior to opening it.
An insulation valve, such as an iris valve, allows the operator to untie the spout but close an access door before discharging the material. For applications involving toxic or hazardous materials, glove box access with positive dust control may be required.
Use Proper Bulk Bag Handling Techniques
Proper handling methods will vary somewhat depending on the type of bag and unloader in use. It’s always best to refer to manufacturer guidelines for use and communicate these guidelines to your team.
The Flexible Intermediate Bulk Container Association (FIBCA) has published a set of guidelines to reduce the risk of injury and to ensure compliance with OSHA regulations. Here are some best practices for safe bulk bag unloading:
- Never suspend an FIBC using less than all of the lift loops provided.
- Never gather the lift loops together onto a single hook.
- Use a sling or other lifting device to keep the loops vertical if lifting with a single hook.
- All forklift tines, crane hooks, adapters and other lifting devices must be free of sharp edges.
- Never allow anyone to stand or place any body part underneath a lifted FIBC.
- Never exceed the safe working load or capacity limit of the bag.
What to Look for in a Trusted Equipment Manufacturer
Choosing the right manufacturer for your bulk bag handling equipment is vital to ensuring safety, efficiency, and long-term reliability in your operations.
- Experience and Reputation: An experienced manufacturer understands the unique challenges of bulk bag handling, ensuring reliable and effective solutions. In contrast, an inexperienced supplier may provide equipment that is ill-suited for your needs, leading to frequent breakdowns and safety risks.
- Understanding of Bulk Bags and Equipment: Manufacturers with a deep understanding of bulk bags can tailor their equipment to your specific requirements. Without this expertise, there’s a risk of receiving generic equipment that fails to handle your materials properly, increasing the likelihood of operational failures.
- Material Testing Capabilities: Robust testing ensures that equipment will perform reliably with your specific materials under real-world conditions. Lack of adequate testing can result in equipment that fails during operation, causing production delays and potential safety incidents.
- Customization Options: The ability to customize equipment to fit your unique operational needs ensures seamless integration and optimal performance. One-size-fits-all solutions may lead to inefficiencies and higher costs as they often require modifications or fail to meet specific process requirements.
- Customer Support and Training: Comprehensive support and training from the manufacturer are crucial for ensuring your team can safely and efficiently operate the equipment. Poor support can result in prolonged downtime, increased maintenance issues, and a higher risk of accidents.
At FormPak, we are proud to be the only manufacturer of bulk bag handling equipment that is a member of FIBCA, and have served on the board for more than 12 years. With over 130 member companies in over 25 countries, FIBCA is committed to safety in every phase of bulk bag usage. FormPak is a key contributor to the up-to-date FIBCA guidelines which serve as industry best practices.
Our industry expertise, combined with the rigorous material testing and product customization we offer, our bulk bags and handling equipment are some of the highest quality available today and are guaranteed to work in your operation.
To learn about safe bulk material handling, check out our Extensive Guide to Safe Bulk Handling & Operations.
