IBC container cleaning in 5 steps: Efficient and safe cleaning

Cleaning an IBC container is substantially different from cleaning an ordinary water tank or silo. An IBC consists of an HDPE inner bottle in a metal cage, with a relatively small opening. Compact and practical, but therefore more difficult to clean properly from the inside.

IBCs are used to store and transport a variety of liquids: from foodstuffs to chemicals and pharmaceuticals. This variation means that cleaning requirements vary greatly from one application to another. What counts as clean in one situation is insufficient in another.

Sebastian Dalhues of Waterkracht sees that difference every day in practice. He guides companies in optimising cleaning processes for IBCs, among others: "The question is not only how you clean, but especially what the end result should be. That differs per sector and per product. You have to design your process accordingly."

Residual residues can disrupt production processes, lead to loss of quality or pose risks to safety and compliance. Consistent and controllable cleaning is therefore a prerequisite for reuse. With the right IBC container cleaner - think rotary nozzles, high pressure and, where necessary, hot water or chemicals - you will make containers demonstrably clean and suitable for the next application.

In this article, we cover...

• The importance of thorough cleaning of IBC containers
• Cleaning methods for IBC containers
• Cleaning in 5 steps

Do you want to know immediately which IBC container cleaner suits your situation? Our specialists will gladly think along with you and show you how to save time, water and costs.

Does an IBC still look clean on the outside? If so, that says little about the inside. Residual liquid, vapours and contamination often remain invisible. That is precisely what makes the risk high: from contaminated product flows to safety problems and rejected containers.

What happens if you don't clean an IBC container properly?

If you leave an IBC untreated or only volatile rinse, residues will remain in the container. The consequences are immediately noticeable in practice:

• Cross-contamination
  Residuals mix with new contents. In regulated industries, this means immediate rejection.
• Undesirable chemical reactions
  Residual substances may react with new products, with risk of gas formation or pressure build-up.
• Quality loss and downtime
  A contaminated container can render an entire batch unusable.

The problem is often not just in whether cleaning is done, but in how consistently it is done. "With a hand lance, you get a different result every time," says Dalhues. "You don't reach the corners properly and the result depends on the user. That makes it difficult to guarantee quality."

Hygiene and safety standards when reusing IBC containers

Do you work in the food, pharmaceutical or cosmetics industry? Then HACCP and GMP prescribe that your containers are always clean and safe. You thus ensure product safety and prevent rejection or sanctions.

• HACCP (Hazard Analysis and Critical Control Points): EU Regulation (EC) No 852/2004 - general food hygiene, mandatory application of HACCP systems
• GMP (Good Manufacturing Practice): Regulation (EC) No 2023/2006 - Good Manufacturing Practice for materials and articles intended to come into contact with food.

At the same time, there is no universal definition of "clean" in practice. The degree of cleaning required depends on the product, the risk and the application. "In one sector, a simple rinse is sufficient, while in food or pharma it must be demonstrably ruled out that residues or bacteria are still present," Dalhues said.

Dalhues said

In some situations, a visual check remains sufficient. In other cases, additional checks are needed, such as testing with indicator strips to determine bacterial contamination.

Safety also plays a role. Any fumes or residue left behind pose a risk to employees, especially when cleaned manually or reused with other substances.

Legal requirements for IBC cleaning in different industries

In addition to hygiene regulations, legal obligations apply. For IBCs containing hazardous substances, the ADR prescribes, among other things, periodic inspections and leakage tests.

Are you reusing an IBC for transport? Then you must be able to prove that the container is clean and safe. Without documentation, a container will be rejected and you will be at risk in case of incidents.

• ADR (Accord européen relatif au transport international des marchandises Dangereuses par Route): European agreement for the international carriage of dangerous goods by road. Implemented in the Netherlands through the Land Transport of Dangerous Goods Act and regulations of ILT (Inspectorate for the Environment and Transport).

Cleaning an IBC requires an approach that suits the application. In practice, automatic systems with high-pressure and rotary tank washing heads have been shown to outperform manual cleaning.

Manual vs automatic IBC cleaning

Manual cleaning with a spray lance or brush takes time and energy. You don't reach all the spots in the container and expose employees to fumes and splashes. The result is also difficult to reproduce.

"You simply don't get everywhere with a hand lance," says Dalhues. "In addition, the result is different every time. That makes it difficult to guarantee consistent quality." On top of that, manual cleaning often uses more water and energy.

An automatic IBC container cleaner operates via a rotating tank wash head placed through the manhole. This rotates horizontally and vertically, creating a 3D spray image.

Instead of manual work, you work with fixed cycles: "A tank wash head runs a full cycle in about 2.5 minutes. Then all surfaces have been hit. Depending on contamination, you repeat that cycle several times."

All things being equal, this yields a consistent result based on prior cleaning tests.

When is chemical cleaning necessary?

Some soiling cannot be removed with water and pressure alone. Think polymers, pigments, glue residues or dried-in food.

In these cases, use a cleaning agent that is matched to the contamination and compatible with the materials of the IBC.

Chemistry is used not only as a supplement, but sometimes also from process requirements. "In the food industry, for example, testing is done with indicator strips," says Dalhues. "If this shows that the cleaning is not sufficient, you have to adjust your process - for example, with chemistry or temperature."

In addition, chemistry can help to clean more efficiently: "With glue residues, you can reduce the pressure required with the right agent. That saves energy and strain on the installation."

The choice of agent also affects the technology. "You need to know what substances are used, because that determines which seals are suitable. In sectors such as the paint industry, customers sometimes work with solvents that have a direct impact on that."

Cleaning an IBC requires a set process. This ensures that every container is safe, hygienic and usable again.

With the step-by-step plan below, you can avoid surprises, rejection and downtime.

Step 1: Preparation - remove residual liquid and carry out inspection

Drain the container completely and dispose of residual liquids according to applicable regulations. Check connections, pallet and cage for damage.

In larger plants, this is often done automatically. "IBCs are tipped or emptied, after which residual flows are disposed of separately," Dalhues said.

Step 2: Remove coarse dirt - first rinse with water

Do a pre-rinse with clean water under low to medium pressure (20-80 bar). This removes loose dirt and prevents caking.

In installations, this is often done with reuse of water to reduce consumption.

Step 3: Deep cleaning - apply high pressure and hot water

A rotating tank wash head cleans the container 360 degrees with high-pressure jets. For stubborn dirt, deploy hot water (up to around 90°C) and chemicals if necessary.

The time required varies depending on the situation: "Liquid sugar is relatively easy to clean, while dried-in oil or polymers require several cycles," says Dalhues.

Step 4: Post-cleaning - rinsing and drying the container

Rinse the container with clean water and remove cleaning agent residues. Then dry the IBC via draining, hot air or a drying process.

Step 5: Verification and certification for reuse

Conduct a visual inspection and additional tests where necessary. Document the cleaning.

In some applications, the container is sealed: "With a seal, you show that the IBC has not been opened again after cleaning," Dalhues says.