Overcoming the Challenges of Steel Drum Emptying: How to Reduce Waste in Industrial Processes

Steel drums, totes and 55-gallon drums are common in industrial processes, but they pose significant challenges when emptying viscous liquids and semi-solids.
These difficulties contribute to product waste, which drives up costs and hinders sustainability efforts.

Reducing waste and streamlining production processes require more efficient solutions, especially in handling and emptying these drums.

The Problem with Steel Drum Emptying

Despite being a common solution for many decades, there are a lot of problems that can be discovered when emptying drums.

Waste Generation and Economic Impact

Steel drums are widely used across industries, but incomplete emptying can leave up to 5% of the product behind.

For 55-gallon drums, this residual waste can result in significant financial losses, especially when scaled to the 1,000-liter capacity (265 US gal) of modern containers.

This waste, combined with the costs of drum pump systems, reconditioning, washing, and collection services, adds unnecessary expenses.

Challenges with Viscous Liquids

Viscous materials like adhesives, silicones, and grease are especially tough to remove from drums.

Narrow openings and rigid walls can make it difficult for even high-pressure pumps to extract contents fully, particularly when dealing with semi-solid materials.

In sectors such as chemical manufacturing, food production, and pharmaceuticals, these residues can lead to contamination, increased costs, and inefficiencies.

Environmental Impact

Residual waste increases the need for cleaning, consuming water and energy.

Additionally, transporting empty drums for reconditioning or cleaning services involves extra costs and environmental tolls, including more emissions from transport vehicles.

Solutions for Maximizing Drum Emptying

Drum pumps, high-pressure pumps, and barrel pumps are popular in various industries. However, they have limitations.

Drum pumps often fail to empty contents fully due to design flaws—small dents can disrupt the process.

High-pressure pumps, while effective, are costly, energy-intensive, and require regular maintenance.

Even the best systems can leave 4-5% of the product behind, particularly with viscous or semi-solid materials.

Industry-Specific Challenges

Different industries face unique drum emptying challenges. For example, food and pharmaceuticals require airtight, closed systems to avoid contamination.

These industries need specialized equipment, but even then, inefficiencies persist, particularly with traditional drum designs.

The Case for Alternative Container Designs

Modern, flexible containers offer a superior alternative to drums, steel totes and 55-gallon drums.

Flexible IBC totes, like Fluid-Bag containers, tackle the challenges by providing larger capacity, durable liners that eliminates the risk of dents, and units that can be collapsed and disposed of after use.

The concept also reduces transportation costs and emissions.