Shipping barrels have come a long way. They started as basic storage containers. Now, they are smart devices with advanced technology. This report builds on what we know about traditional shipping drums. It explores new ideas, green practices, and creative uses changing the industry.

Types of Shipping Drums

Steel Shipping Drums

Steel drums remain one of the most durable options for shipping and storage. They are made from steel, stainless steel, cold-rolled steel, or carbon steel. First, the bottom and top sections are created. Then, the sides are rolled and welded on. These drums offer exceptional resilience and cost-effectiveness for long-term use.

Key features of steel drums include:

• Superior strength compared to plastic or fiberboard alternatives
• Reusability for multiple shipping cycles
• Potential for interior plastic lining to accommodate various liquids
• Not suitable for acidic materials due to corrosion risk

Steel drums follow U.S. regulations (49 CFR § 178.504) and have these identification codes:

• 1A1 for non-removable head steel drums
• 1A2 for removable head steel drums

Steel drums are the best choice for the environment. They are fully recyclable. Each year, more steel is recycled than all other materials put together. Reconditioning steel drums cuts CO2 emissions by 68% compared to making new ones. This makes reconditioned drums a smart choice for eco-friendly businesses.

Plastic Shipping Drums

Plastic drums are the most popular shipping containers. They are versatile and lighter than steel drums. This weight advantage translates to lower shipping costs.

These drums are typically made from:

• Thermoplastics including PVC, high-density polyethylene (HDPE), nylon, and polystyrene
• Manufacturing processes including blow molding (extrusion, injection, and injection stretch)
• UN classifications of 1H1 (non-removable head) and 1H2 (removable head)

Plastic drums are well-suited for:

• Liquids, dry powders, or granular materials
• Chemical storage requiring corrosion resistance
• Applications where weight is a significant cost factor

Recent innovations feature the EcoBalance PCR Plastic Drum. It is made from about 50-75% recycled HDPE sourced from post-consumer resin (PCR). This method keeps materials out of landfills. It turns them into new drums. This process uses less energy and helps companies meet their sustainability goals.

Fiber/Fibre Drums

Fiber drums provide a lightweight, cost-effective alternative to metal or plastic containers:

• Constructed from layers of heavy-weight virgin kraft paper
• Tops secured with steel rims and lever clamps
• Primarily designed for dry goods transportation
• Can be coated inside with:
  • Aluminum
  • Polyethylene
  • Colored kraft
  • Polyester
  • Silicone
  These materials ensure liquid compatibility.
• Fully recyclable when their useful life ends

Other Drum Types

Additional specialized drum options include:

Aluminum Drums (1B1/1B2): These drums need to be made of aluminum that is at least 99% pure or from an aluminum base alloy. They weigh less than steel drums. This means lower transport costs and easier lifting and handling.

Composite Drums: The 6HA1 composite steel drums have a plastic inside and a steel outside. Benefits include the strength and durability of steel drums. They also offer the chemical compatibility found in polyethylene drums.

Drum Specifications and Measurements

Standard Sizes and Dimensions

The 55-gallon (208-liter) drum is standard in the industry. However, drums also come in different sizes for various shipping needs. According to Skolnik Industries’ measurement chart:

Capacity (Gallons/Liters)	Diameter	Height	Maximum Weight
5 / 19	14”	10”	10 lbs.
20 / 76	18.25”	19.25”	30 lbs.
30 / 114	18.25”	27.50”	35 lbs.
55 / 208	22.50”	33.00”	60 lbs.
110 / 416	30”	41”	102 lbs.

A standard 55-gallon steel drum typically measures:

• Height: 33.00” or approximately 84 cm
• Diameter: 22.50” or approximately 57 cm

A full 55-gallon drum can be quite heavy. “Fifty-five gallons of water weighs 459 pounds, so with the drum, it can weigh about 500 pounds.”

UN/DOT Certification Requirements

Shipping drums for hazardous materials must pass strict tests. This is to comply with UN and DOT rules. These certifications ensure containers can safely transport potentially dangerous substances.

North Coast Container notes that drums must undergo four specific tests annually:

1. Drop test
2. Leak proofness test
3. Hydrostatic pressure test
4. Stacking test

These tests are performed annually, with recertification required every 12 months. After finishing, manufacturers give customers test reports. These reports show certification and performance results for each container. All testing must comply with the general requirements for packaging testing.

Applications and Best Practices

Common Uses

Shipping drums are used across numerous industries:

Chemical Storage: Store and transport hazardous chemicals safely with UN-certified barrels. Built for durability and chemical resistance, these drums are ideal for industrial applications.

Oil Transport: Plastic drums offer safe, leakproof storage for oils and lubricants. They meet the needs of both automotive and industrial uses.

Hazardous Material Transport: These drums ensure safe transport and storage. They reduce risks when handling toxic or dangerous materials. These shipments must comply with Federal Hazardous Materials Regulations.

Dry Goods: Great for fiber drums. They can ship dry or solid items like clothing and other consumer goods.

Wine and Spirits Aging: Special barrels have sensors. They track temperature, fluid levels, and conditions. This helps ensure the best aging for alcoholic drinks. These smart barrels use predictive modeling. They can spot problems with wine or whiskey as they age. They rely on methods like Logistic Regression.

Drum Closure Systems

Drum closures vary by material and application:

By material, they can be divided into:

• Metal drum closures
• Plastic drum closures
• Metal and plastic hybrid drum closures

By head type:

• Open-head drums have removable covers. They close with bolt rings or a lever lock. These drums are usually used to ship solid materials and thick liquids.
• Closed-head/tight-head drums: Better suited for more fluid liquids.

Specific closure options include:

• Nylon and plastic drum caps are often used with flammable goods. They melt at high temperatures. This melting helps prevent pressure build-up and explosions.
• Steel drum plugs come in 2” and ¾” sizes. They offer different gasket and coating options. This ensures they work well with your packaged products.
• Stainless steel closures work well for food packaging drums. They are also ideal for seasonings, specialty chemicals, and high-purity products.

Stacking and Securing Guidelines

Proper stacking practices are essential for safety and efficiency:

For plastic drums, the Plastic Drum Institute recommends:

• Four-high stacking (16 drums) only under ideal conditions
• Three-high as the typical maximum stack height for full plastic drums
• Two-high when negative factors like high temperatures are present

Important stacking considerations include:

• Using level concrete floors
• Properly constructed double-faced pallets
• Maintaining temperatures below 90°F
• Avoiding direct sunlight exposure
• Following UN ratings for contents and specific gravity

To secure single drums during transport, we have specialized products. Single Drum Securement quickly and easily holds one or two 55-gallon steel drums on a pallet. It also has European CTU certification, making it suitable for Hazmat products.”

Drum Liners and Accessories

Drum liners serve multiple purposes:

• Preventing product contamination
• Minimizing drum wear and tear
• Reducing cleaning requirements between uses
• Extending container lifespan

Liner options include:

• Anti-static liners to reduce static buildup
• Rigid straight-sided liners to prevent slippage
• Seamless accordion liners with pleated sides for flexibility
• Various bottom configurations including round and straight designs

Smart Drum Technology and IoT Integration

Internet of Things (IoT) in Shipping Containers

Modern shipping containers, including drums, are being transformed by IoT technology. Smart containers with IoT sensors are a game-changer for supply chain visibility. They help eliminate blind spots. A smart container is a regular shipping container that uses IoT technology. Sensors inside send real-time data about different parameters.

Key features of smart containers include:

• Self-powered IoT gateway devices installed onto existing containers
• Sensors that gather and relay information on container status and cargo conditions
• Multiple communication protocols to transmit data to cloud-based platforms
• Web-based applications that allow stakeholders to access asset data from anywhere

These smart containers enable:

• Detailed condition monitoring of contents
• Accurate real-time tracking across all transportation modes
• Prevention of theft, smuggling, spoilage, or damage
• Improved route planning and delay prevention

Drewry’s 2022/2023 report says smart containers will increase eightfold in five years. This change marks a big shift in the shipping industry.

Climate-Controlled Smart Shipping Containers

Climate-controlled smart shipping containers are vital for sensitive items. These include medicine, perishable foods, cosmetics, and advanced technology. They ensure the right environmental conditions are maintained. These specialized containers:

• Use IoT sensors to adjust to changes in temperature, humidity, and airflow.
• Enable real-time data collection for monitoring and managing containers during transit.
• Provide an extra layer of safety and security for cargo
• Automatically adjust to maintain stable internal conditions despite external environmental changes

This technology is a big step up from older shipping containers. Those needed constant human care to keep the inside conditions right.

Smart Cable Drums

Smart Cable Drums use advanced smart drum technology in the electrical industry. These innovative drums:

• Are aware of their exact position via GPS tracking
• Know precisely how much surplus cable length they carry
• Transmit this information wirelessly regardless of global location
• Use sensors and radio transmitters combined with tailor-made algorithms to process movement data
• Transmit via 2G-4G mobile radio technology to a cloud portal

This technology allows for new business models like Pay Per Use. Here, customers only pay for the cable they use. The drum’s sensors measure this precisely. The system alerts manufacturers when more delivery is needed. It also helps prevent cable theft using positioning technology.

Sustainability and Recycling

The Complete Life-Cycle of Steel Drums

Steel drums use a circular economy model. This model reduces environmental impact throughout their entire life cycle.

1. New Steel Drums: These drums are made from recycled steel. They can be reconditioned many times.
2. Filling: Used to transport various materials safely
3. Emptying: After use, drums are made ready for collection
4. Collection: Only certified drip-dry empty drums are accepted for reconditioning. They must have original labels intact and all closures secure.
5. Reconditioning: This lets us reuse drums. It saves natural resources and keeps them out of landfills.
6. Recycling: If drums can’t be reconditioned, they get recycled into new products.

Reconditioning Process

Reconditioned steel drums are a green and sustainable packaging option. They’re great for companies that use and throw away many steel drums each year. The reconditioning process generates 68% less CO2 than manufacturing new drums.

The reconditioning process involves:

• Collecting used, empty drums
• Cleaning and inspecting each drum
• Repairing any damage
• Repainting and refurbishing as needed
• Testing to ensure quality and compliance with standards

Orlando Drum cleans and recycles industrial-grade drums. This helps keep them out of landfills and protects the public. These drums are either fixed up and sold for refilling or cleaned and made into scrap. The scrap can be used for new products like drain pipes and flower pots.

Economic and Environmental Benefits

The sustainability benefits of proper drum recycling and reconditioning include:

• Significant reduction in CO2 emissions
• Conservation of raw materials
• Reduction in energy consumption
• Lower costs compared to purchasing new drums
• Keeping potentially hazardous containers out of landfills

Orlando Drum says reconditioned steel drums usually cost much less than new ones. They also deliver nearly the same performance. This allows companies to save money while protecting the environment without sacrificing quality.

Transportation and Logistics

Cost-Effective Shipping Methods

When shipping drums across long distances, several methods can optimize costs:

1. Nesting: Putting smaller drums inside larger ones cuts shipping costs. It saves space. For example, if you ship a drum kit, nest the shells and take off the hardware. This can lower shipping costs a lot.
2. Specialized Shipping Services: UPS and FedEx offer packing and shipping for drums. They also offer full insurance coverage.
3. Alternative Carriers: Before, companies like Greyhound offered low-cost shipping for large items. They stored these items in their luggage compartments.
4. Online Marketplaces: Services like Reverb and eBay often get shipping discounts. This can lower costs a lot compared to shipping directly.

Tracking and Management Systems

Modern tracking systems for drums and containers have evolved significantly:

1. Connected Drums: This tech uses IoT for 24/7 drum tracking. It detects theft, tracks shipments, and sends alerts during drum cycles.
2. AI Integration: Advanced systems leverage AI and edge computing. This lets each drum “know” how much material is left. When empty, it can automatically request a pickup.
3. Cost Savings: Tracking systems can save money. Customers usually lose about 10% of their drum fleet each year. For large distributors, this loss can add up to millions of euros each year.

Specialized Applications

Intelligent Drum Interfaces in Music

Beyond industrial shipping, drum technology has advanced in other fields. In music, the Drum Intelligent Trigger Interface (DITI) is a top technology. It converts traditional drums into MIDI. This technology:

• Can handle up to 24 trigger inputs for converting even large drumsets to MIDI
• Powers and converts force-sensitive resistor (FSR) drum triggers to MIDI
• Features 1024-bit A/D converters to capture playing dynamics
• Incorporates training capabilities that adapt to individual performance styles

Barrel Monitoring for Wine and Spirits Industry

The wine and spirits industry now uses smart tech. Barrel bung wireless sensor packs:

• Collect and communicate readings to monitoring systems
• Sense parameters from within aging barrels
• Use transceivers to send signals to computer systems for analysis
• Alert end users via SMS or email when parameters reach abnormal profiles
• Allow for temperature profile monitoring of multiple barrels within a storage facility

These systems create data models of barrel environments over time. They build profiles to spot deviations and predict potential issues during aging. They use methods like Logistic Regression for this.

For more details on packaging specifications, check Part 178 regulations. Look specifically at Subpart M for testing non-bulk packagings and packages.