Best Practices for Bulk Bag Unloading in Industrial Settings

Bulk bags or Flexible Intermediate Bulk Containers (FIBCs) have changed how industries ship and store high volumes of dry products. From agriculture to construction, manufacturing to mining, these heavy-duty bags help ensure you can handle your materials as efficiently and cost-effectively as possible. However, to maximize these benefits from bulk bags, all appropriate bag unloading and bag handling operations must be followed. 

At Comsyn, we realize that in addition to the timely handling of bags, safety, efficiency, and longevity are important aspects of operations. That’s why our woven fabric FIBCs are made from the strongest industrial manufactured materials. This blog will work through some of the basic dos and don’ts of bulk bag handling, as well as suggested bulk bag handling equipment and systems to improve efficiencies in your operations.

The Dos of Bulk Bag Handling

1. Choose the Appropriate FIBC Bulk Bags

Always check with the supplier to make sure that the FIBC is compatible with the material type, weight, and environmental conditions. Choosing an appropriate bag is the first step to successfully unload the bag and transport the material.

2. Review the Instructions Label

Every bag has a label specifying the safe working load (SWL) as well as the filling ratio and guidelines for handling. Not adhering to this label can lead to dangerous situations.

3. Examine Reusable FIBCs 

Inspect any reusable FIBCs for rips, fraying loops, or damaged discharge spouts. Even a small defect could compromise the integrity of the bag when unloading a bulk bag.

4. Check the Discharge Spout

The discharge spout should be secured before transport. Leaking or poorly tied spouts can cause spills or loose products when handling.

5. Verify Stability

When staging a balance, loading and stacking are everything. An unbalanced bulk bag can tumble and cause injury or waste.

6. Properly Close the Top Inlet

Be sure to secure the top of the bag to prevent contamination, spillage, and exposure to external factors.

7. Employ Equipment Capable of Lifting Weight

Utilize forklifts, cranes, or hoists designed for the full weight of the complete bag. Safety hazards and equipment failure can occur if the load exceeds equipment capacity.

8. Use Lifting Devices of Appropriate Size 

Ensure that forks, hooks, and/or slings are sized to the FIBC loop size to ensure proper weight distribution.

9. Avoid Ignition 

Because of Static Electricity handling flammable material, use static dissipating or groundable bags, and if possible, work in a grounded environment to mitigate ignition risk.

10. Protect from Environmental Conditions

Store and handle the FIBC in dry, shaded conditions. UV light and moisture can cause a breakdown in the bag standards after prolonged exposure.

11. Secure Load During Transportation

When moving a bag, whether in a truck or container, the bag should be secured in the cargo, at a minimum with straps or other restraints to prevent the bag from shifting and/or rolling over.

The Don’ts of Bulk Bag Handling

1. Avoid Selecting FIBCs Without Expert Advice

Choosing the incorrect bag intentionally or by accident, without consulting an expert, may result in structural failure or poor bag unloading. 

2. Do Not Exceed the Safe Working Load (SWL)

Overloading a bag can cause it to rupture while lifting, jeopardizing the product and worker safety.

3. Avoid Uneven Loading

Loading bulk bags evenly will obtain equilibrium and structural strength and assist in handling bulk bags.

4. Avoid Starting and Stopping Abruptly

Abrupt motion while in transit can shift the load, causing damage to both the FIBC and the handling equipment.

5. Do Not Snatch Lift the FIBCs

Always lift the bag slowly, as sudden or abrupt movements may damage the seams or lifting loops.

6. Do Not Allow Workers Under Suspended Loads

Never allow workers to pass or stand under a suspended FIBC. This is considered a huge safety hazard and is not an acceptable practice in any industrial safety program.

7. Avoid Overhang

Position the bulk bag properly on the pallet or transport surface to avoid pounds on either side of the pallet or transport surface.

8. Do Not Stack Bags While Unstable

Stack only bags that are ​designated for stacking on flat surfaces. Unstable stacks have the propensity to fall.

9. Do Not Use in Extreme Conditions Without Approval

If the products you are transporting are corrosive or at an unusual temperature, be sure you consult your supplier on compatibility before use.

10. Do Not Reuse Single-Trip Bulk Bags

Single-use or one-trip FIBCs are not made for sustainability or longevity. Reusing the bags may lead to failure while the bag is being handled on the truck or transported.

Bulk Bag Unloading & Handling Tips

Safely discharging a bag will protect both the contents and the operator’s safety and efficiency. 

Consider the following practices: use a designed bulk bag unloading station that supports the entire bag structure during discharge; properly align the discharge spout with your hoppers or feeders to avoid spillage; train your worker to understand the bulk bag handling system and safety measures; and avoid using sharp tools while emptying a bag as it could damage the FIBC. 

Maintaining clean areas where materials are spilled to avoid slipping accidents where materials have been spilled.

Bulk Bag Handling Equipment Options

There are several bulk bag handling systems available to help optimize operations and improve safety:

1. Bulk Bag Unloaders

These specially designed unloading stations allow for safe and efficient unloading of bags while reducing the need for manual engagement.

2. Bulk Bag Lifting Devices

Forklifts, cranes, or hoists with spreader bars or bag-lifting frames are safe for handling FIBCs.

3. Bulk Bag Dischargers/Dispensers

These systems allow for flow control of material and are useful for feeding processing equipment or packaging lines.

4. Bulk Bag Hoppers

Hoppers direct materials from the bag to silos or mixers, minimizing waste and dust.

5. Bulk Bag Stands

They stabilize bags during the filling or bag-unloading process, and they ensure that the bags stay upright and properly supported.

The proper bulk bag handling equipment will make operations more manageable, reduce safety risks, and prolong the life of your bags.

Comsyn’s Premium Bulk Bag Solutions

At Comsyn, we are proud to offer industry-standard, woven fabric bulk bags that are built for performance and durability. Each bulk bag is designed to manage a variety of materials, such as powders, grains, chemicals, and aggregates, and adheres to rigorous global standards.

Features include:- 

• High tensile strength woven fabric
• UV stabilized for outdoor use
• Custom dimensions, lifting loops, and discharge options
• Reusable options for multiple trips
• Compatible with most bulk bag handling systems

Comsyn bulk bags are the preferred option for businesses looking for safety, consistency, and efficiency with bulk bag unloading and transport.

Conclusion

It all begins with effective and safe bag unloading, which requires proper use of not just the right bulk bag handling equipment and durable FIBCs but also the bulk bag you chose and its pre-use inspection. By steering clear of common errors and utilizing best practices to safely and efficiently unload bags, you will greatly minimize risks for employee injuries, material loss, and equipment malfunction.

With advanced bulk bag handling systems, durable FIBCs, and the expert support of a trusted supplier of bulk bag handling systems like Comsyn, your industrial operations can adhere to standards of health and safety, plus a successful implementation. 

Whether your material to unload is powder, grain, or chemical, utilizing the above-stated approaches will help you operate an efficient, optimized, and future-proof FIBC bulk bag system. 

FAQs

• What is a bulk bag unloader?

A bulk bag unloader is specialized bulk bag handling equipment designed to safely and efficiently discharge materials from FIBCs.

• Can bulk bags be reused?

Yes, certain FIBCs are designed for multiple uses but always inspect them before bag handling or bag unloading.

• Are bulk bags waterproof?

Standard bulk bags are not fully waterproof, but laminated or lined FIBCs offer improved moisture resistance for safer bulk bag handling.

• How do you empty a bulk bag?

You can empty a bulk bag using a big bag unloading system with a controlled discharge spout to ensure safe and clean material flow.