Picking the right FIBCs for your business is all well and good. However, if you want to streamline your operation and maintain a secure working environment, you need to think about safe handling best practices. Confused about various FIBC categories? Need some guidance on safe handling and proper storage? Read on for everything you need to know.
Safe handling starts before the first bag arrives on site. If a bag is the wrong size, strength or static type for your product, careful lifting won’t make it safe. Before you order, talk your supplier through three things: what you’re filling, how you’ll move it, and where the bag will be filled and emptied.
Start with your product’s bulk density. A tonne of mineral sand takes up far less space than a tonne of plastic pellets, so a bag that fits one product well can be undersized or oversized for another. Match the bag’s base to your pallets so nothing overhangs the edge. Then check that the safe working load (SWL) on the label covers your full fill weight. Single-trip bags are typically built to a 5:1 safety factor and reusable bags to 6:1, so only reuse a bag that was designed for it.
Your industry narrows the options further. A bag that works for agricultural products may not be approved for chemical manufacturing. Food-grade and pharmaceutical products need bags made in certified hygienic facilities, and dangerous goods need UN-certified bags tested for that product’s packing group.
If your product or the air around it is flammable, static electricity becomes the deciding factor. The IEC 61340-4-4 standard sorts FIBCs into four types based on how they handle static charge.
Type A bags are plain woven polypropylene with no static protection. Keep them away from flammable powders and any area where flammable gas or vapour may be present.
Type B bags use a fabric with low breakdown voltage that stops high-energy propagating brush discharges. They can carry dry flammable powders, but they aren’t safe where flammable solvents or gases are present. They don’t need grounding.
Type C bags have conductive threads woven through the fabric, linked to a ground tab. They only protect you while they’re connected to a verified ground point, before and during filling and emptying.
Type D bags use static-dissipative fabric that releases charge through harmless low-energy discharges, with no ground connection needed. That takes away the risk of someone forgetting to clip on the ground cable.
Type A | Type B | Type C | Type D | |
Fabric | Standard woven PP | Low breakdown voltage PP | PP with interwoven conductive threads | Static-dissipative PP |
Static protection | None | Blocks propagating brush discharges | Drains charge to ground | Dissipates charge into the air |
Grounding required | No | No | Yes, before and during use | No |
Dry flammable powders | No | Yes | Yes | Yes |
Flammable gas or vapour present | No | No | Yes, when grounded | Yes |
Typical uses | Non-flammable minerals, sand, aggregates | Dry flammable powders in non-flammable surroundings | Chemicals, pharma, fine powders in classified zones | Same as Type C, where grounding is hard to guarantee |
If you’re unsure which type fits your process, compare Type C and Type D bags or ask your supplier to review your filling setup. Whichever you choose, the FIBCA Safe Handling Guidelines are clear that a Type C bag must never be filled or emptied around flammable materials until a secure ground connection is in place.
Every bulk bag needs a quick check before it’s filled or lifted, even if it came straight off the delivery truck. Damage that looks cosmetic, such as a nicked loop or a frayed seam, can be enough to drop a full bag. If you find damage that could affect the bag’s strength, the guidelines are clear: take it out of use and speak to your manufacturer or supplier before anyone handles it.
Work through these points on every bag:
Checkpoint | What to look for | If it fails |
Label | Safe working load, safety factor, static type and UN marking (if required) are present and readable, and match your product | Don’t use the bag until you’ve confirmed its rating with your supplier |
Lift loops | Cuts, fraying, burns, twisting or loose stitching where loops join the body | Remove from use |
Body fabric | Holes, tears, abrasion, brittleness or fading from UV exposure | Remove from use |
Seams | Open, broken or skipped stitches, especially along the base | Remove from use |
Spout and fill duffle | Ties present and intact, and the discharge spout closed the way the manufacturer specifies before filling | Close it correctly or replace the ties |
Liner (if fitted) | Punctures, and liner secured to the bag | Replace the liner or the bag |
Ground tab (Type C only) | Tab present, undamaged and labelled | Don’t use it in a flammable environment |
Moisture and contamination | Damp patches, mould, residue from previous contents or chemical exposure | Quarantine the bag and recycle damaged bags |
Pallet | The right size for the bag, with no overhang and no protruding nails or splinters | Swap the pallet |
Lifting equipment | Tines, hooks and bars free of sharp edges, with latches working on crane hooks | Fix or replace before lifting |
For a more detailed walkthrough, see our guides on how to read an FIBC label and how to inspect a UN-certified FIBC on delivery.
Bags that have sat in a warehouse for months need the same checks, plus one more question: are they still as strong as the day they arrived? No industry body sets a fixed shelf life for FIBCs, because UV exposure, temperature, humidity, and how the bags were stored all affect how they age. The reliable approach is to pull samples from older stock and run top-lift and UV tests against the standards in ISO 21898:2024. Ask your supplier about storage limits if your bags or liners use anti-static additives, since these can lose effectiveness faster than the base fabric.
When it comes to filling and discharging bulk bags, the FIBC offers a comprehensive safety checklist. During discharging, all lift loops should be used. Although individual loops are incredibly robust, they are designed to be used together. Failure to do so can result in a single loop tearing and a bag dropping during discharging. What’s more, you should never use a single hook to gather multiple loops. Meanwhile, loops should be kept vertical at all times.
The safe working load of every FIBC should be clearly labeled. Never exceed this during filling. When filling, make sure that materials are evenly distributed. This maintains stability, ensuring the bag won’t topple over during discharging or filling. Once filled, bulk bags should be securely closed. This is particularly important when transporting a FIBC bulk bag, but even a stored bag can leak if it hasn’t been closed properly. If the FIBC bags you’re using have a discharge spout at the bottom, ensure these are also closed before you attempt to fill them.
You also need to consider the environment you’re working in. If you’re dealing with flammable or explosive materials, you need to be mindful of the risk posed by static electricity. To prevent accidental injury or worse during filling and discharging, make sure you’re using a Type C or D bag in these situations.
Whatever equipment you use must be designed to handle FIBCs, rated for the full weight of a filled bag, and fitted with safety latches on any hooks. Check tines, bars, and hooks before every shift. Sharp edges cut lift loops, so FIBCA calls for edges rounded to at least 5 mm. Keep everyone clear of the lift zone, and make sure only trained operators move bulk bags.
Treat every bulk bag move with care. Set the tine spacing so all loops hang vertically. Carry the bag close to the mast, as low as possible, with the mast tilted back, and never tilt it forward under load. Stop the forklift before raising or lowering, keep a clear line of sight, and never drag or push a bag along the floor. Once the bag is down, remove the full load from the loops before withdrawing the tines.
Lift on every loop the bag was built with, using latched hooks. Only gather loops onto a single hook if the manufacturer designed and approved the bag for it, and use slings to keep the loops vertical. Raise and lower the bag smoothly, with no sudden lifts or stops, and never let anyone stand or reach under a suspended bag. If you’re grounding a Type C bag through the hook, keep it free of paint, oil, and dust. For more on matching loops to your equipment, see our FIBC lifting loop types comparison.
A bag that has fallen over is unstable and may already be damaged. Clear the area, then lift it upright using slings and all of its lift loops. Never push it back up by hand or with the forklift tines, and inspect it fully before it goes back into use.
The most important thing to remember when storing full and empty FIBC bags is to keep them in a secure and clean environment. Moisture and UV rays can damage the integrity of bulk bags, so exposure to the elements should be avoided. For added protection, bags should be covered at all times to minimize dust and moisture intrusion.
When stacking bags, it’s best to follow a supported stacking or pyramid method. With the supported stacking method, bags should be placed evenly against at least two retaining walls. With the pyramid stacking method, you’ll create a base layer of filled bags, before adding ever-decreasing tiers to form a pyramid shape. However, when using this stacking method, you need to ensure every layer is resting on at least four bags.
When transporting FIBCs, make sure every bulk bag is properly secured. As well as being dangerous, unsecured FIBC bags can lead to unwanted spillages, rendering stored materials unfit for purpose.
Use this table as a quick reference on the warehouse floor or in operator training.
Do | Don’t |
Choose a bag approved for your product, industry and filling environment | Use a Type A bag with flammable powders or near flammable vapours |
Inspect loops, seams, fabric and labels before every fill and lift | Handle a damaged bag without checking with your supplier first |
Ground Type C bags before and during filling and emptying | Reconnect a ground cable that came loose mid-process |
Close the discharge spout correctly before you start filling | Fill past the safe working load printed on the label |
Keep the filled height within 2:1 of the bag’s width | Fill unevenly, which leaves the bag leaning or unstable |
Use every lift loop, with latched hooks or correctly spaced tines | Gather loops onto one hook unless the bag is approved for it |
Carry bags low and close to the mast, with the mast tilted back | Tilt the mast forward or make sudden lifts and stops |
Stop the forklift before raising or lowering a bag | Drag or push a bag across the floor |
Keep everyone clear of the lift zone | Let anyone stand or reach under a suspended bag |
Store bags indoors, dry and out of sunlight | Stack bags that aren’t designed for it, or stack without a pyramid or supported method |
Use pallets that fit the bag, with no nails or overhang | Approach a damaged bag in a stack before removing the bags above it |
Most bulk bag incidents start with a small decision: the wrong static type, a skipped inspection, a loop left off the hook. Get those basics right and FIBCs remain one of the safest, most cost-effective ways to move bulk material. Choose a bag rated for your product and environment, check it before every lift, and train your operators to follow the same rules every shift.
If you’re reviewing your handling process or aren’t sure which bag type fits your product, Codefine’s packaging specialists can help you match the right FIBC bulk bags to your operation.
You’ll be able to lift a bulk bag with one hook only if the manufacturer designed and approved the bag for single-point lifting, such as a one-loop or two-loop bag. Never gather the loops of a standard four-loop bag onto one hook. When single-hook lifting is approved, use slings or a lifting frame to keep each loop vertical and avoid sideways strain.
No, type D bags don’t need to be grounded. Type D bags use static-dissipative fabric that releases charge safely without a ground connection, which removes the risk of someone forgetting to clip on a ground cable. You still need to ground nearby conductive equipment and personnel when handling flammable products. Type C bags are different: they must be grounded before and during filling and emptying.
There’s no single limit on how high you can stack filled bulk bags. Still, there are safety limits. Safe stack height depends on the bag’s design, its safety factor, your product’s density and how stable the filled bags are. Only stack bags built for stacking, and use a pyramid or supported method.
The safety factor shows how much more than its safe working load a bag can hold in testing before it fails. A 5:1 bag rated at 1,000 kg withstands 5,000 kg, which is standard for single-trip bags. A 6:1 rating is used for multi-trip bags built for repeated use under controlled conditions.
No industry body sets a fixed shelf life for FIBCs. How long a bag lasts depends on UV exposure, temperature, humidity, construction and storage conditions. Keep empty bags indoors, dry and out of sunlight, and test samples from older stock for top-lift strength before use. Bags with anti-static additives may degrade faster, so check with your supplier. (57 words)
No. Single-trip bags are built to a 5:1 safety factor for one fill and discharge cycle. Reusing them risks seam or loop failure under load, even if the bag looks undamaged. If you need to reuse bags, choose multi-trip FIBCs rated at 6:1 and follow a documented inspection and reconditioning process.
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