How can you avoid the risks associated with handling drums by filling them on pallets?

In many industrial processes, drum handling is a regular but risky operation. With weights that can reach several hundred kilos, moving them exposes operators to musculoskeletal disorders (MSDs) and workplace accidents.

To limit these risks while optimizing productivity, innovative solutions have been developed. Filling small drums directly on a pallet is an effective method that eliminates unnecessary handling. Other alternatives exist, such as assisted handling or robotization, but they often present constraints in terms of costs and flexibility.

Let’s see why the on-pallet filling solution stands out as a safe and high-performance alternative.

Risks related to traditional drum handling

Handling drums, kegs, and barrels can quickly become a source of danger in industrial environments. Between their imposing weight and the need to transport them from one point to another, the risks are numerous and can impact both worker safety and operational efficiency.

1. A weight difficult to handle

Full drums represent a heavy and bulky load. Handling them involves risks of crushing in the event of a fall, significant physical exertion that can cause injury, and complex logistics for their storage and transport.
 

2. Impact on operator health

Lifting and moving drums manually, especially oil drums, leads to back and joint pain, increases cases of MSDs, and generates increased fatigue that can affect concentration and increase the risk of accidents.
 

3. Risk of accidents and loss of productivity

Incidents related to the handling of kegs and drums can lead to:

• Spills of dangerous products, pollution, creation of ATEX zones, contamination, product loss, and recycling difficulties...
• Production interruptions and possible damage to equipment and machinery
• Increased costs related to injuries and compensation.

Filling drums directly on pallets: an ergonomic solution

1. How does an on-pallet filling system work?

• Automatic or manual pallet feeding via a pallet dispenser
• The drums are pre-positioned by the operator on a pallet before filling (e.g., 4 x 4 or 6 x 4)
• The dosing system ensures precise filling by using a weighing scale upstream or directly on the pallet according to the required precision
• No lifting or moving is necessary after filling
• Closing the drums and placing lids is performed by the operator.

2. Considerable time savings

This solution optimizes operations by:

• Eliminating superfluous handling.
• Reducing packaging time.
• Improving production rates.

3. A 100% secure solution for operators

• No more manual lifting of full drums.
• Less physical fatigue and risk of injury.
• A safer working environment that complies with safety standards.

Alternatives to on-pallet filling

1. Unitary drum filling and assisted handling solutions

Drum filling can be carried out on a unit-by-unit basis, with individual handling of each drum after filling. This method requires operator intervention at every stage, which increases the risk of MSDs and slows down production processes.

2. Assisted handling with vacuum lifting tubes

• A jib crane system with a vacuum lifting tube lifts the drums.
• Reduces physical effort but still requires manual intervention.
• Effective solution but limited in speed, as the operator must be precise when positioning the drums on the pallet.

3. Process robotization with robotic arms

• Automatic handling without intervention, precise and fast.

This solution can be considered for high production rates or sensitive processes involving toxic or explosive products with the Palamatic Drumbot.
 

4. Automatic drum palletizer

• Intended for large-scale continuous flow production.
• Full automation but high costs.
• High-performance solution but unsuitable for small and medium-sized productions.
• Significant equipment footprint, requiring a dedicated and secure zone.

The PalDrum-04 is an efficient solution adapted to all industries needing secure and optimized drum filling. With compatibility for various formats and materials, this technology offers increased productivity and a fast return on investment.

Conclusion

Filling drums directly on the pallet is an innovative solution that addresses both safety and productivity challenges. 
👉 What if your next filling line combined safety, ergonomics, and performance? Contact us today to discuss it.