Optimising the filling of industrial containers: methods, tools and best practices

In an economic climate where controlling logistics costs is becoming crucial to a company's competitiveness, optimising container filling is an essential performance lever.

This operation, often underestimated in the supply chain, can generate substantial savings when carried out correctly.

Our expertise in this area enables us to offer you an in-depth analysis of the methods, tools and practices that transform container filling into a competitive advantage.

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The choice of an appropriate filling method depends on several factors, including the nature of the products, the volumes handled and the specific operational constraints of each industry. Let's take a look at the main approaches currently in use.

Manual filling: a traditional approach with obvious limitations

Manual filling, although still practised in some industries, has major drawbacks.

During a recent visit to a chemical manufacturer, I observed three operators working for nearly 45 minutes to fill a single IBC container.

This method not only results in limited productivity, but also exposes operators to ergonomic risks and the potential inhalation of hazardous substances.

The limitations of manual filling are numerous:

• Approximate dosing accuracy
• High product contamination risks
• Restricted production rate
• Difficult to guarantee traceability
• Exposure of operators to occupational hazards

Semi-automatic filling: a compromise

Semi-automatic systems are an intermediate step towards full automation. They combine human intervention and mechanical assistance to improve process efficiency.

These solutions generally incorporate weighing devices and handling aids that reduce the drudgery of operations.

This hybrid approach is particularly suitable for medium-sized companies or production processes requiring a certain degree of flexibility. It significantly improves productivity while limiting the initial investment.

Automatic filling: operational excellence

Automatic filling systems, such as the IBCFill01, represent the state of the art in container packaging. This equipment incorporates advanced technologies that guarantee precision, repeatability and safety throughout the process.

The operating principle of an automatic system such as the IBCFill01 is based on several coordinated steps:

• Precise positioning of the container
• Automatic format detection and validation
• Adjustment of filling parameters
• Real-time weight control and dynamic flow rate adjustment
• Finalisation of filling with maximum precision
• Automatic generation of traceability data

Full automation enables unrivalled levels of performance, with rates exceeding 20 containers per hour depending on the application.

(To learn more about the technologies involved, check out our case study on automated loading of veterinary powders.)

Precision dosing systems

Dosing accuracy is a key factor in optimising filling. Current technologies enable remarkable levels of accuracy to be achieved, with deviations of less than 0.1% on containers weighing several hundred kilograms.

The IBCFill01 incorporates a dynamic weighing system that adjusts the filling rate according to the mass already transferred. This approach optimises cycle time while ensuring maximum accuracy.

A manufacturer of veterinary products using this technology has reduced material losses by 3.2%, representing an annual saving of more than £65,000.

Management and optimisation software

Specialised software plays a crucial role in optimising filling. In particular, it enables:

• Planning of packaging operations
• Optimisation of manufacturing recipes
• Management of filling parameters according to product
• Collection and analysis of production data
• Generation of performance reports

These IT tools can be integrated into existing production management systems (ERP, MES) to provide a comprehensive and consistent view of the packaging process.

Containment and emission management devices

Specific devices are essential for powdery products or those that emit VOCs (Volatile Organic Compounds). Modern systems such as the IBCFill01 incorporate containment technologies that ensure:

• Capture at source of dust and vapours
• Filtration of emissions before release
• Possible recovery of captured products

These devices meet regulatory requirements while helping to improve working conditions and reduce material losses.

(For more information on applicable standards, please refer to the recommendations of the INRS on the prevention of risks related to dust emissions.)

Regulations relating to the transport of goods

The transport of goods packaged in containers is subject to various international regulations that must be strictly observed:

• The ADR (European Agreement concerning the International Carriage of Dangerous Goods by Road)
• The IMDG (International Maritime Dangerous Goods) code for maritime transport
• The IATA regulations for air transport

These texts define, in particular, the conditions for filling containers, load limits and labelling requirements.

The IBCFill01 includes features that facilitate compliance with these requirements, such as automatic fill level control and printing of regulatory labels.

Industrial safety and hygiene standards

Filling operations must also comply with strict safety and hygiene standards:

• ATEX directives for explosive atmospheres
• ISO 22000 standards for food safety
• Good Manufacturing Practices (GMP) in the pharmaceutical industry

The design of the IBCFill01 takes these various requirements into account, with specific versions certified for explosive environments or food and pharmaceutical applications.

(For more information on regulatory requirements in the field of industrial handling, consult the guide to good practices in handling published by the European Union.)

Optimal volume calculation and load distribution

Optimising the volume used in a container can generate significant savings. Accurate calculation of the available volume and careful load distribution allow you to increase the quantity of product transported while complying with authorised weight limits.

The IBCFill01 incorporates algorithms that automatically calculate the optimal fill rate based on product characteristics and regulatory constraints. This advanced feature ensures that the best compromise between quantity transported and safety is always achieved.

Standardisation of filling procedures

Standardisation of procedures is an often underestimated lever for optimisation. It enables you to:

• Reduce cycle times
• Minimise operational errors
• Facilitate operator training
• Improve the traceability of operations

Process automation with the IBCFill01 naturally imposes this standardisation, with predefined sequences and systematic checks that guarantee the repeatability of operations.

Integration into a continuous improvement approach

Filling optimisation is part of a broader continuous improvement approach. The collection and analysis of production data identifies opportunities for improvement and measures the impact of corrective actions.

Automatic systems such as the IBCFill01 automatically generate this data, facilitating the implementation of a structured continuous optimisation approach.

(Find out how this approach was implemented in our case study on the manufacture of chemical premixes.)

Underestimation of stability constraints

Load stability is a critical factor for transport safety. Inadequate weight distribution can lead to serious accidents, particularly during handling operations or transport. Automatic systems incorporate features that contribute to load stability, such as automatic centring of the product in the container or weight distribution control.

Neglect of ergonomic aspects

Manual filling operations expose operators to significant ergonomic risks, such as awkward postures, excessive effort and repetitive movements. These constraints can lead to musculoskeletal disorders (MSDs) with costly consequences for the company.

Automation with the IBCFill01 eliminates these risks by removing tedious manual operations. Operators are reassigned to supervision and control tasks, thereby enhancing their skills while protecting their health.

Insufficient traceability

In an increasingly demanding regulatory environment, the traceability of packaging operations is becoming an essential requirement. The absence of reliable data can lead to non-compliance with potentially serious consequences.

Modern systems such as the IBCFill01 automatically generate a complete history of operations, recording critical parameters such as container ID, exact weight, date and time, operator responsible, etc. This data can be stored and used to demonstrate compliance.

In the food industry: precision and food safety

A manufacturer of specialised food preparations recently optimised its packaging process using the IBCFill01. The results speak for themselves:

• 2.8% reduction in material losses
• 35% improvement in throughput
• Elimination of cross-contamination
• Full traceability of operations

The hygienic design of the equipment, with smooth surfaces and materials that comply with food requirements, particularly appealed to this customer, who was looking for a solution compatible with its food safety constraints.

In fine chemicals: risk control and precision

The fine chemicals sector imposes specific constraints in terms of safety and precision. The experience of a chemical premix manufacturer perfectly illustrates the benefits of filling automation:

• Total containment of hazardous products
• Dosing accuracy of ±0.1%
• 37% increase in productivity
• Improved working conditions

The return on investment was achieved in less than 18 months, thanks to savings in labour costs and reduced material losses.

Optimising container filling is not limited to installing high-performance equipment. It is part of a comprehensive approach that encompasses the entire supply chain, from product design to shipment.

The IBCFill01 fits perfectly into this holistic approach, offering a modular solution that can be adapted to different industrial contexts. Its robust design, advanced features and integration capabilities make it a strategic piece of equipment for companies looking to optimise their packaging processes.

To explore the possibilities for optimising your container filling operations, our experts are available for a customised study of your specific needs. An analysis of your current process will identify areas for improvement and quantify the expected benefits of automation with the IBCFill01.

📩 Would you like to modernise your production? Contact our experts for a customised study!