Flexible Intermediate Bulk Containers (FIBCs), or bulk bags, are essential in modern warehouses, construction sites, factories, and supply chains, providing businesses with an efficient way to transport and store large volumes of material. Whilst these robust containers can withstand the rigours of handling, storage, transport, and exposure to the elements, and can accommodate multiple reuse cycles when properly maintained, their longevity and performance depend on correct storage and handling practices.
In this article, we examine the main FIBC handling guidelines to safeguard your team and your products.
1. Protect Your Bags From The Elements
The first rule of bulk bag storage is to keep your FIBCs protected from rain and the elements where possible. Whilst bulk bags are designed to be robust and weather-resistant, prolonged exposure to UV sunlight, precipitation, and temperature fluctuations can reduce their lifespan over time. Ideally, both empty and filled bags should be stored in a clean, covered facility, shielded from moisture and direct sunlight. Extended exposure to harsh weather can gradually affect the polypropylene fabric of your bulk bags and cause the stitching to deteriorate around the seams, potentially weakening structural integrity.
If you must store your bags outside as a short-term measure, ensure they are placed on a protective surface to prevent ground moisture absorption, and cover them securely with a waterproof tarp.
2. Stack And Support Your Bags Correctly
Stacking FIBCs saves valuable warehouse space, but it must be done safely. Always follow the manufacturer's instructions and the guidelines set out in ISO 21898:2024. As a general rule, maintain a filled bag height-to-base ratio at or below 2:1 unless your supplier specifically approves a different configuration. This prevents the stack from becoming unstable and creating a safety hazard.
Ensure that your pallets fully support the base of each bag without any overhang, as this can cause stress points and lead to bag failure. Pyramidal or supported stacking methods are often the most effective storage strategy, where each bag in the upper layer rests on at least four bags below it. Never stack bags that are leaning or damaged.
3. Manage Your Electrostatic Risk
Some powdered or granular products generate static electricity during filling and emptying, creating an ignition risk in environments where flammable dust or vapours are present. It is therefore essential to choose the correct type of FIBC for your product, working environment, and risk profile. The four main types are:
- Type A: Standard bulk bags with no electrostatic protection. Do not use them around flammable or potentially explosive products and gases.
- Type B: Bags made from materials that prevent propagating brush discharges, but they do not dissipate charge.
- Type C: Conductive bags that must be earthed or grounded during filling and emptying to safely dissipate the static charge.
- Type D: Antistatic bags that fully dissipate the charge safely into the atmosphere without requiring grounding.
Using the wrong type of bag can present a serious safety risk, so always ensure your chosen FIBC meets the required standards for your facility, such as IEC 61340-4-4.
4. Safe Working Loads And Reuse
Many bulk bags can be used multiple times, but this is not universally the case. Bags with a 5:1 safety factor are designed for single trips and must not be refilled. Reusing them can cause the bag to fail, putting operators and product at risk. Only bags specifically designed and certified for multiple uses, such as those with 6:1 and 8:1 safety factors, can be safely reused. Even then, we recommend a thorough inspection before each reuse.
Check carefully for visible damage, including cuts, torn or loose stitching, and compromised lifting loops. If a bag shows any sign of wear and tear, it should be removed from service and replaced. It is also important to adhere to the manufacturer's safe working load limits and avoid overfilling. Most bags are designed to be filled to no more than three-quarters capacity, as exceeding this increases the risk of spills and structural failure.
5. Implement An Effective Stock Rotation System
FIBCs do not have a universal and officially endorsed shelf life, so even bags rated for multiple uses degrade at different rates. The rate of degradation depends on the quality of the bag material's UV inhibitors, manufacturing quality, and the conditions in which they are stored and handled. To minimise risk, it is prudent to apply a 'first in, first out' (FIFO) stock rotation system, in which older bags are used before newer ones.
This approach spreads your risk and minimises the potential for age-related degradation and failure. Using bags beyond their recommended shelf life is also risky, as there may be structural defects in the material that are not immediately obvious from a visual inspection. Always follow the specific shelf-life guidance provided by your bulk bag supply partner, even if a bag appears to be in good condition.
What Next?
Cliffe Packaging is one of the UK's leading suppliers of FIBC bulk bags, from UN-certified and antistatic bags to food grade, ventilated, baffle, and eco-friendly FIBCs. Whether you need to handle hazardous goods or flowable powders, our experienced team can guide you to the right bag for your application. No guesswork, just reliable results. To find out more, please contact us today by clicking here.
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