Chapter 11 Use and handling of packaging Section 11.0 General information

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1 Section 11.0 General information Contents 11.0 General information Contents Introduction 11.1 Packaging material for areas with explosive atmospheres Antistatic, dissipative and conductive packaging Removal of plastic film within explosion hazardous areas Marking of plastic packaging suitable for use in explosions hazardous areas 11.2 Filling and sealing of packaging Use of venting stripes with PE open head drums Hot filling Closing torques of packaging 11.3 Unloading of chemicals Unloading of chemicals in a closed loop procedure 11.4 Use, handling and transport of packaging Use of composite IBC / handling with pallet trucks Cargo securing measures Formation of loading units 11.5 Labelling Adhesion of labels (see German version) 11.6 Storage Type of storage for chemical pallets (CP) (see German version) Safe stacking of boxes (see German version) Status: October 2012 Packaging Handbook 1

2 Section 11.0 General information Introduction Packaging, even if designed and produced state of the art, can fulfil its task only, if it is applied in an appropriate manner during all kinds of handling. Imprudent or improper use can negate any efforts and cost done beforehand. For a safe and reliable function of packaging users need detailed knowledge of how to use it in a proper way. When in doubt, users shall ask their manufacturers for detailed application instructions. All other parties, involved in the handling of packaging or packed goods, e. g. storage of empty packaging, filling, warehousing of packed goods, conduction of transportation safety measures and much more are include. Of course, also customers are a part of the supply chain, and consequently packaging can suffer damages and even accidents by improper handling. This chapter offers hints for the proper use of packaging in daily practice. Particular emphasis is on such issues, which have been asked most frequently in the past. Status: October 2012 Packaging Handbook 2

3 Section 11.1 Packaging material for areas with explosive atmospheres Antistatic, dissipative and conductive packaging While filling or emptying plastic from packaging types ignition of flammable atmosphere can be caused by electrostatic charges collected on plastic surfaces. This danger can only be avoided by taking appropriate measures at locations used for filling or unloading these packaging types. In particular, antistatic, dissipative and conductive packaging types have to be used in order to prevent generating electrostatic charges. Suitable antistatic, dissipative or conductive packaging types have to be specified with packaging manufacturers. The manufacturer shall warrant a minimum bleeder resistor, which should be a part of the packaging specification as well as of the manufacturer s regular production monitoring. Whether a certain type of packaging meets the specific requirements or not has to be decided by the filler taking the complete application of the packaging into consideration. Design and construction of filling and unloading equipment shall be done by experts only. Moreover, such equipment has to be inspected on a regular basis and shall be operated by specially trained people only. As a valuable assistance the collection of examples published by the (German) Berufsgenossenschaft is recommended. Status: October 2012 Packaging Handbook 3

4 Section 11.1 Packaging material for areas with explosive atmospheres Removal of plastic film within explosion hazardous areas Separation of insulating film from solid basic bodies / statements from TRBS 2153 Objects made of insulating materials can accumulate electrostatic charge by rubbing or other operational activities. By bringing an object or a person in close contact to such dangerously charged surfaces ignition hazards can be triggered. Therefore it the use objects or facilities made of insulating materials must be avoided in explosive hazardous areas. During handling procedures, like removing shrinking film from cargo units and packaging, such dangerous charging can appear. Removing insulating film from solid basic bodies / cargo units must therefore be carried out outside the zones 0 and 1. If this is a regularly recurring work step and such discharges must be expected during routine operations, these handling procedures are not permitted in zone 2 either. Status: October 2012 Packaging Handbook 4

5 Section 11.1 Packaging material for areas with explosive atmospheres Marking of plastic packaging suitable for use in explosion hazardous areas Avoidance of electrostatic charging of objects and facilities / Statements from TRBS 2153 Objects or facilities may not be charged dangerously in explosion hazardous areas. Such objects or facilities are e.g. films, packaging, containers including possible coatings, linings or similar measures, but also textile objects, e.g. FIBCs. Therefore the use of objects or facilities made of insulating materials, e.g. synthetic materials, in explosion hazardous areas has to be avoided. If conductive materials, e.g. metallic materials, cannot be used alternatively, measures against dangerous charging have to be taken. Possible measures for packaging made out of plastic are e.g. the use of antistatic additives, outer layers or grids made of conductive or dissipative materials, conductive or dissipative coatings, conductive threads into textiles or the limitation of the dimensions of surfaces by structural design which can be charged. To prevent mixing up of packaging made out of plastic which are suitable to be used in explosion hazardous areas and those which are not, a uniform and if possibly durable marking is recommended showing the approval for the use in explosion hazardous areas and if necessary additional labels with safety instructions for a proper handling of the packaging. The compilation of safety instructions for filling, transport and emptying should consider the following issues: - Which rules and standards apply, which location for operations is allowed (exzone 1and 2)? - Which liquid products (classification of explosion groups) are allowed to be filled in packaging? - What is strictly forbidden when using packaging (e.g. flammable atmosphere, use of ex-zone 0)? - What is demanded when using packaging (e.g.: earth, to minimize the speed of filling and unloading actions)? - What is to be avoided (blending and stirring procedures, immediate re-filling after cleaning)? In particular electrostatic secured composite IBC are to be marked by safety instructions for their use because the antistatic protection is mostly not recognisable and mix up should be avoided. Generally labels with coloured background (e.g. yellow) are used, containing information in the language of the user (e.g. German and/or English, see German version). Status: October 2012 Packaging Handbook 5

1 Use of venting stripes with PE open head drums Usually PE open head drums are delivered including so-called venting stripes to the filler s sites.

6 Section 11.2 Filling and sealing of packaging Use of venting stripes with PE open head drums Usually PE open head drums are delivered including so-called venting stripes to the filler s sites. Venting stripes avoid that hot drum bodies are sealed tight by the top drawn up during production process. Without venting stripes evolving vacuum would distort a freshly produced drum body. These venting stripes have to be removed before closing a filled drum in any case. If they are left in the drum s top, the top s gasket will not be able to seal the drum tightly. Status: October 2012 Packaging Handbook 6

7 Section 11.2 Filling and sealing of packaging Hot filling In some cases it is necessary, to fill products at higher temperatures. Beyond the usual danger of erythema by contact with hot materials, hot packaging can cause additional problems. For instance, hot filled packaging may not be closed after the filling, occurrence immediately closely, because the cooling down of the product and the contained air forms a low pressure. This may result in serious damages of the packaging used, which subsequently cannot be shipped any more. However, even when no permanent deformations take place occur, slight distortions are usual, which can have considerable impacts on the save stack ability of these packed goods. Another consequence of high temperatures may be damages to the various gaskets. This may result in reduced tightness, and due to venting of the arising vacuum in unfavourable cases considerable quantities of rainwater may intrude. Additional problems may occur with packaging types made from thermoplastic materials. These materials lose a considerable part of their stability even with only moderately higher temperatures. In particular, those packaging types are not stackable in this state. Additional problems caused by vacuum have been described before. Consequences resulting from hot filling procedures are manageable, e. g. by incomplete closing, so that vacuum can be compensated until the product has cooled down to ambient temperature. Plastic packaging may not be stacked until cooled down completely. For hot filling into PE open head drums venting stripes, which are installed in the top for manufacturing reasons, can be used for avoiding undesired vacuum as well. After complete cooling and before shipping the venting stripes have to be removed in any case. Tight head packaging types can be closed for the cooling phase either with special plugs including venting valves or with the loosely-closed original plug. After cooling is complete the plugs have to be closed with the required closing torque. Status: October 2012 Packaging Handbook 7

8 Section 11.2 Filling and sealing of packaging Closing torques of packaging According to ADR, chapter 4.1, packaging, including bulk containers (IBC) and large packaging, shall be constructed and closed so as to avoid any loss of contents when prepared for transport under normal conditions of transport, by vibration, or by changes in temperature, humidity or pressure. In order comply with these requirements the use of well defined closing torques is essential. However, it is not possible to list concrete technical values here, because they are highly dependent on the specific types as well as the materials used. The manufacturer has to be asked for the recommended closing torque of a specific packaging item. Even for the shipment of empty packaging an optimum closing torque is important. If the closure has not been closed tightly enough, venting will happen due to variations in temperature. Humidity contained in intruding atmosphere may condense inside of the packaging and therefore cause, for instance, damages by corrosion or subsequent product pollution by rust. In extreme cases improperly closed packaging can even contain considerable quantities of rainwater aspirated in by vacuum. In general, repeated opening and closing procedures can damage gaskets of plugs. Therefore it is recommended to use the minimum required closing torque for empty packaging only. The closing torque recommended by the manufacturer shall be used for the final closing of the filled packaging for the first time. In particular, this closing torque is important for dangerous goods packaging in order to be in full accordance to the UN-approval. Materials used for gaskets today, are affected in different ways by multiple closing and opening operations. Improper use may even chip off particles, which may cause contamination of the product. Gaskets made from thermoplastics tend to cold flow under too high pressures caused by too high torques. Cold flow means the flow to another permanent shape due to pressure at only ambient temperatures. Therefore, an originally perfectly sealing gasket may change its shape, so that its proper function cannot be fulfilled reliably later on. So it is essential to conduct the final closing either with a torque spanner or an adjustable and well monitored machine. Status: October 2012 Packaging Handbook 8

9 Section 11.3 Unloading of chemicals Unloading of chemicals in a closed loop procedure The use of chemicals requires specific procedures, which protect human beings and the environment from chemical impacts as well as, vice versa, protect highly pure chemicals from impurities caused by human beings or the environment. These requirements can be achieved, for instance, with so-called closed product loops. For this method a suitable unloading system bridges the raw materials supply unit on the one and the production plant on the other side. So-called dip tube systems are well available equipment for the implementation of such a closed loop for liquid products. Their basic elements are the dip tube itself, a quick-release fastener and a dispense head. While the dip tube remains in the transportable raw materials container, the dispense head usually is a part of the production plant. For the unloading operation, which is run by pumping usually, the dip tube is connected to the dispense head by the quick-release fastener. Special features: The dispense head can be locked in one direction by a unidirectional restrictor valve. The dip pipe connection is available with usual drum closing threads. Cheap dip pipes allow single trip applications. Special types are available, e. g. electro statically dissipative version useful for flammable liquids. Status: October 2012 Packaging Handbook 9

10 Section 11.4 Use, handling and transport of packaging Use of composite IBC / handling with pallet trucks Pallets of composite IBC can roughly be divided up into two mainly used groups: 1. Wooden pallets, specially designed for the particular IBC-type 2. Galvanized steel pallets with an integrated bottom plate which carries the inner receptacle. This particular type of composite IBC can suffer problems which are described below. In general, steel pallets (see 2.) are constructed in a way, that its clearance allows transportation by fork lifts as well as by pallet trucks. However, daily practice shows that hard drop offs of heavily loaded containers can cause permanent deformations of the IBC s bottom plate. In consequence the remaining clearance may no longer be wide enough for the use of pallet trucks. This can result in considerable operational problems, if no suitable forklifts are available. In order to avoid such a dilemma, a test is recommended to find out whether or not a particular composite IBC type is appropriate for a certain operational area. In a simple test procedure a contestant is filled with water up to its nominal capacity and lifted with a fork lift on one side only up to 10 cm. With a rapid move the fork is removed from the pallet, so that this container side drops hard to the floor. If the clearance of the pallet remains wide enough to use the pallet truck equipment this IBC-type should withstand even coarser handlings in daily practice. If the clearance is no longer wide enough for the pallet truck types used a different type of composite IBC is recommended; where appropriate, the test is carried out with additional weight. The pushing of the composite IBC and not the raising and lowering with pallet trucks is not appropriate and may result in damage to the IBC. Status: October 2012 Packaging Handbook 10

11 Section 11.4 Use, handling and transport of packaging Cargo securing measures Suitable cargo securing measures are a major important factor for safe transportation of packed goods on trucks as well as in ISO-containers. Therefore the following slogan hits the mark: Safe stowing does not only prevent damages to packed goods, but also avoids harm to human beings and our environment. This motto was already used as an introduction in the Handbook of Cargo Securing published by VCI in 1993, which has been amended by an additional brochure in Today the Manual of Cargo Securing Measures of Packed Goods is available, which has been collated in close cooperation of various German associations BAM, VCI, VCH, BGL, DSLV, BGS and police organizations. This manual can be downloaded Status: October 2012 Packaging Handbook 11

12 Section 11.4 Use, handling and transport of packaging Formation of loading units One loading unit is a collation of single packages e.g. on one pallet as a unit for transportation on e.g. a truck/container. For unit formation legal requirements e.g. hazardous regulations, traffic regulations have to be observed. Moreover, the responsible persons must assure that the quality of shipment and storage also meets cost efficiency. In addition to observing general regulations, each individual case has to be checked. The less the individual loading units are secured, the greater the necessary load securing measures must be in the truck/container. Procedure 1. Establishing stapling and securing specifications for loading units ready for shipment (e.g. pallets): Defining the maximum compression of the packaging units to be stapled and secured Determining the pallet to be used Determining the stapling (e.g. on the pallet) Determining the height of the loading units 2. Stapling and securing of commissioned loading units Assembling the packaging material for a loading unit Aim at assembling similar packaging sizes Heavy packages for dispatch and packaged liquids belong in the lower layers Lighter, flexible and pressure-sensitive packages for dispatch belong in the upper layers Maximum stapling height should not exceed one meter If possible, packages for dispatch should be of uniform height Bags must be packed horizontally On top of packages for dispatch with air vents no different packages may be placed Empty spaces within the loading unit are to be avoided or filled. Status: October 2012 Packaging Handbook 12

13 Section 11.4 Use, handling and transport of packaging Formation of loading units 3. Stapling and securing of loading units e.g. in container, truck Dangerous labelling must be visible Packages for dispatch containing liquids must be placed with the closures upright Damaged packages are not to be included in the loading unit Packages for dispatch must be secured so that its position cannot changed within the assemblage Packages for dispatch may not be damaged by securing measures Comply with requirements for securing in truck, container 4. Compliance with regulations Implementing the stapling and securing regulations Instructing the staff members Conducting and monitoring Status: October 2012 Packaging Handbook 13

14 Section 11.5 Labelling Adhesion of labels See German version Status: October 2012 Packaging Handbook 14

15 Section 11.6 Storage Type of storage for chemical pallets (CP) See German version Status: October 2012 Packaging Handbook 15

16 Section 11.6 Storage Safe stacking of boxes See German version Status: October 2012 Packaging Handbook 16

(4) Production inspection is the inspection that must initially be conducted on each newly manufactured IBC.

(4) Production inspection is the inspection that must initially be conducted on each newly manufactured IBC. Subpart O Testing of IBCs 178.800 Purpose and scope. This subpart prescribes certain testing requirements for IBCs identified in subpart N of this part. [Amdt. 178 103, 59 FR 38074, July 26, 1994, as amended