When an IBC tote arrives at our Earth City facility, it begins a journey that determines whether it will be reconditioned for reuse, recycled into raw materials, or transformed into something entirely new. Here's what that process looks like from start to finish.
Arrival and Intake
Trucks arrive daily carrying anywhere from 1 to 20+ IBC totes per load. Each incoming container is immediately:
1. Photographed for documentation 2. Weighed (full weight indicates remaining contents) 3. Tagged with a unique tracking number 4. Assessed for visible condition and hazard indicators
If a container arrives with unknown or potentially hazardous contents, it's isolated in our containment area until proper identification and handling procedures are determined.
Sorting and Grading
Within 24 hours of arrival, each IBC goes through our initial assessment:
Bottle inspection: We check for cracks, UV degradation, chemical staining, deformation, and wall thickness. Bottles are categorized as: reusable as-is, reusable after cleaning, recyclable only, or hazardous waste.
Cage inspection: We check for structural integrity, weld condition, alignment, corrosion, and stacking member condition. Cages are categorized as: ready for reuse, repairable, or scrap steel.
Pallet inspection: Checked for cracks, warping, forklift damage, and structural integrity.
Valve and fittings: Checked for function, seal condition, and thread integrity.
The Reconditioning Line
IBCs selected for reconditioning enter our cleaning bay:
Step 1 — Drain and prep. Any remaining contents are properly managed. Food-grade residues go to composting. Chemical residues are handled per EPA guidelines.
Step 2 — Disassembly. The bottle is lifted from the cage. Valve is removed. Old gaskets are discarded.
Step 3 — Bottle washing. Our automated wash system performs a three-cycle clean: hot alkaline wash (140°F), sanitizing rinse, and fresh water final rinse. Our closed-loop system recycles 85% of process water.
Step 4 — Inspection. Clean bottles are inspected under bright lighting. Any bottles with cracks, excessive wear, or contamination that didn't clear are pulled for recycling.
Step 5 — Cage repair. Bent members are straightened. Weak welds are reinforced. Corrosion spots are treated. Label plates are cleaned.
Step 6 — Reassembly. Clean bottles are reinstalled in repaired cages with new gaskets and seals. Valves are replaced if worn.
Step 7 — Pressure test. Every reassembled IBC is filled with water and pressurized to verify leak-free performance.
Step 8 — Grading and labeling. Passed units receive their grade (A or B for reconditioned), reconditioning date, and tracking number.
The Recycling Line
IBCs that can't be reconditioned are broken down:
- HDPE bottles are granulated into plastic flakes by our industrial shredder
- Steel cages are cut and baled for metal recycling
- Pallets are either repaired for reuse or sent to wood/plastic recycling
- Valves and fittings are sorted by material for appropriate recycling
By the Numbers
On an average day, our facility processes 40-60 IBC totes. Of those: - Approximately 60% are reconditioned for reuse - Approximately 35% are recycled (materials recovered) - Approximately 5% require special handling (hazardous residues) - Less than 2% of total material goes to landfill