Intermediate Bulk Container (IBC): Types, Uses, Design, Safety & Industry Applications

By Jiten Patel | December 4, 2025

Packaging solutions in the world used in the industrial sectors are safe, efficient, and cost effective. The Intermediate Bulk Container (IBC) is one of the solutions which have revolutionized the storage and transport of bulk materials.

IBCs are known to be very durable, have high capacity and are multifunctional in the sense that they have found use in most industries including the chemicals industry, food industry, pharmaceutical industry, agriculture sector, petrochemical industry, waste water treatment and many more.

This is the ultimate guide to intermediate bulk containers with all the information about the type, design, materials used, benefits, usage, safety, cleaning, reconditioning, lifecycle, sustainability effect and other key purchasing decisions.

What Is an Intermediate Bulk Container?

An Intermediate Bulk Container (IBC) is a reusable or single-use, industrial grade container that is used in the safe storage, handling, and transportation of liquids, semi-liquids, viscous, powders, pastes, and granulated substances.

The design of IBCs allows them to be very space-saving due to their high volume capacity, and their footprint size is comparable to a pallet.

Common Features of IBCs

  • Cube-shaped design
  • Capacity between 500 to 3000 liters
  • Stackable frame
  • Pallet-compatible base
  • Top filling cap and bottom discharge valve.
  • Constructed of economical substances (HDPE, steel, stainless steel, composite).

Why Are They Called “Intermediate”?

They fall between:

  • Small drums (200L)
  • Large tank containers (20,000L+)

Hence the name intermediate bulk container.

History & Evolution of Intermediate Bulk Containers

The solution to a significant industrial problem was the invention of IBCs:

The way to carry more bulk of items without the inefficiency of small drums and the rigidity of large tanks.

Key Milestones

  • 1960s-1970s: Metal IBCs on chemicals were invented.
  • 1980s: HDPE plastic IBCs were introduced.
  • 1990s: Composite caged IBCs gain international standard.
  • 2000s: Flexible IBCs (FIBCs) transform the process of handling dry bulk.
  • 2020s: IBCs with RFID sensor tracking and internet of things sensors come in.

In the current day, IBCs have become indispensable in industries in which safety, efficiency and compliance are paramount.

Types of Intermediate Bulk Containers

There are various types of IBCs based on material, structure and purpose. A breakdown is provided below.

Rigid Intermediate Bulk Containers

Rigid IBCs are tough, strong units that are composed of:

  • High-density polyethylene (HDPE)
  • Carbon steel
  • Stainless steel
  • Composite (steel + plastic)

Features

  • Integrated pallet base
  • Stackable frame
  • Ideal for hazardous and non-hazardous materials
  • Capacities: 275 gallons (1040L) & 330 gallons (1250L) are most common

Applications

  • Chemicals
  • Oils
  • Food liquids
  • Pharmaceuticals
  • Petrochemicals

Rigid IBCs have the greatest durability and have a life span of years when well maintained.

Collapsible Intermediate Bulk Containers

Collapsible IBCs have the ability to creep down when not in use and this saves on return-shipping cost as well as storage space up to 75%.

Benefits

  • Space-saving
  • Hygienic (replaceable liners)
  • Lightweight
  • Ideal for food-grade and pharma products

Industries

  • Cosmetics
  • Pharmaceuticals
  • Dairy
  • Beverage manufacturing

They usually contain inner bags of plastic and an outer frame that can be reused.

Caged Intermediate Bulk Containers

Caged IBCs are the most widely used IBC type globally.

Structure

  • Blow-molded HDPE inner bottle
  • Galvanized steel cage exterior
  • Pallet base (wood, steel, or plastic)
  • Top fill port (150mm or 225mm)
  • Bottom discharge valve (2-inch)

Advantages

  • Affordable
  • Easy to maneuver
  • Ideal for liquids & chemicals
  • Reusable
  • Available as:
    • New
    • Rebottled (new bottle + used cage)
    • Reconditioned (cleaned and reused both)

Such industries as agriculture, paints, chemicals, food ingredients, and detergents are controlled by such IBCs.

Flexible Intermediate Bulk Containers (FIBCs)

Also known as:

  • Big bags
  • Jumbo bags
  • Bulk bags
  • Super sacks

Features

  • Made from woven polypropylene
  • Designed for dry, flowable materials
  • Capacity: 500 kg to 2000 kg
  • Options:
    • U-panel
    • 4-loop
    • Circular
    • Baffle bags
    • Conductive bags (for static-sensitive materials)

Used For

  • Grains
  • Sugar
  • Fertilizer
  • Sand
  • Minerals
  • Plastic granules

FIBCs are quite lightweight, cost-effective and ideal with bulk dried goods.

Materials Used to Manufacture IBCs

The choice of material lies on its chemical compatibility, stability and cost, and other factors based on the industry needs.

High-Density Polyethylene (HDPE)

Most common material for plastic IBCs.

Benefits

  • Resistant to chemicals
  • Lightweight but strong
  • Food-grade variants available
  • BPA-free
  • Cost-effective

HDPE can be used in general chemicals, water, non-corrosive liquids, and beverages.

Carbon Steel IBCs

Used for:

  • Oils
  • Solvents
  • Petrochemicals
  • Industrial liquids

Advantages

  • High structural strength
  • Good for flammable liquids
  • Long lifespan
  • Easy to repair

Stainless Steel (304/316)

Applied in the industries that require purity and corrosive industries.

Benefits

  • Hygienic
  • Corrosion-proof
  • Perfect for food and pharmaceuticals
  • Withstands extreme temperatures

Used for winery, distilleries, dairy, pharmaceuticals, and acids.

Composite IBCs

Made from:

  • HDPE inner tank
  • Steel cage outer body

Blends the toughness of steel and the chemical resistant attribute of plastic.

Engineering Design of IBCs

IBCs follow a highly engineered design to maximize space, efficiency, and safety.

Key Design Features

  • Cube shape → 25% more capacity than cylindrical drums
  • Stackable frame → Multiple IBCs can be stored vertically
  • Pallet base → Compatible with forklifts and pallet jacks
  • Top fill port → Quick loading
  • Bottom discharge valve → Easy unloading
  • Four-way forklift access
  • UN/DOT certification for hazardous materials

IBIS needs to be subjected to strict tests that ensure the test is durable and spill-free.

Advantages of Using Intermediate Bulk Containers

The IBCs have numerous advantages over drums, barrels, and other industrial packaging solutions.

Space Efficiency

  • Cube design utilizes warehouse space better
  • Stacks easily
  • 1 IBC = 5 drums (approx.)

Better Transport Efficiency

  • Reduced shipment cost
  • Pallet-sized footprint
  • Easy handling with forklifts

Enhanced Safety

  • UN approved hazardous materials.
  • Designed to prevent leaks, spills, and contamination

Versatility

Stores:

  • Liquids
  • Powders
  • Semi-solids
  • Pastes
  • Chemicals
  • Food products

Cost Savings

  • Reusable units
  • Lower labor cost
  • Reduced packaging waste

Environmental Benefits

  • Many IBCs are recyclable
  • Reconditioning programs reduce waste
  • Lower carbon footprint than drums

Uses and Applications of Intermediate Bulk Containers

IBCs have applications across almost every industrial sector.

Chemical Industry

Used for:

  • Acids
  • Solvents
  • Alkalis
  • Hazardous liquids
  • Detergents
  • Additives

The certification of safety is essential in this industry.

Food & Beverage Industry

IBCs are used to transport:

  • Corn syrup
  • Fruit pulp
  • Oils
  • Vinegar
  • Chocolate
  • Juices
  • Dairy ingredients

Stainless steel or food-grade HDPE is preferred.

Agriculture

Used for:

  • Pesticides
  • Fertilizers
  • Liquid nutrients
  • Animal feed liquids

FIBCs are used for dry products like grains.

Pharmaceutical & Cosmetics

Used for:

  • Gels
  • Lotions
  • Liquid chemicals
  • Intermediates
  • Active ingredients

Cleanliness and hygiene standards are essential.

Petrochemical Industry

Stores:

  • Fuel
  • Lubricants
  • Solvents
  • Adhesives
  • Resins

Carbon steel IBCs are common.

Water Storage & Treatment

Used for:

  • Rainwater harvesting
  • Emergency water supply
  • Wastewater treatment
  • Greywater systems

Aquaponics and hydroponics tend to use clean IBCs.

Construction & Mining

Used for:

  • Sand
  • Cement
  • Aggregates
  • Admixtures

FIBCs dominate this segment.

Choosing the Right Intermediate Bulk Containe

When selecting an IBC, consider:

Type of Product

  • Liquids → Rigid or caged IBC
  • Dry materials → FIBC
  • Hazardous → UN-certified IBC
  • Food → Stainless steel or food-grade plastic

Material Compatibility

Check chemical compatibility charts to avoid reactions.

Capacity Requirements

Common sizes:

  • 500L
  • 800L
  • 1000L
  • 1250L
  • 1500L

New vs Reconditioned vs Rebottled

  • New → Highest hygiene
  • Rebottled → New bottle + used frame
  • Reconditioned → Fully cleaned and reused

Industry Certification

Look for:

  • UN/DOT
  • IMDG
  • FDA (for food grade)
  • NSF
  • ISO

Safety Standards for IBCs

Safety is a critical factor in the design and use of intermediate bulk containers.

Fire Safety

Plastic IBCs can melt in fire, releasing contents.
For flammable materials, use:

  • Carbon steel IBC
  • Stainless steel IBC

Handling Safety

  • Always use forklifts or pallet jacks
  • Follow weight limits
  • Secure during transport

Labeling Requirements

Hazardous goods must display:

  • UN number
  • Hazard class
  • Compatibility details

Leakage Prevention

Regular checks for:

  • Valve integrity
  • Cap tightness
  • Cage stability
  • Cracks or punctures

Maintenance, Cleaning & Reconditioning

Reconditioning prolongs life of IBCs and wastes are minimized.

Cleaning Process

  • Emptying the container
  • Steam or chemical cleaning
  • Pressure washing
  • Drying
  • Inspection
  • Valve replacement
  • Leak testing

Reconditioning Types

  1. Rebottled IBC
    • New plastic bottle + used cage
  2. Reconditioned IBC
    • Cleaned bottle + cleaned cage
  3. Washed IBC
    • Economical but not for sensitive materials

Environmental Impact & Sustainability

IBCs support sustainable industrial practices.

Environmental Benefits

  • Reduced packaging waste
  • Long service life
  • Lower CO₂ output than drums
  • Recyclable materials
  • Supports circular economy

Future of Intermediate Bulk Containers

The future of IBCs includes:

  • Smart IBCs with sensors
  • Digital tracking (RFID, IoT)
  • Stronger, lighter materials
  • Enhanced safety features
  • Sustainable manufacturing

Conclusion

The contemporary bulk material handling has turned into intermediate bulk containers. They are essential in almost all sectors of industries due to their durability, efficiency, versatility and safety.

IBCs are of incomparable value and performance whether they are involved in transportation of hazardous chemicals or storing of food ingredients and even in handling of dry materials.

Their affordability, space-saving nature, and the ability to fit into most industries make IBCs have the potential to remain a fundamental part of the global supply chain decades into the future.