Case Study: Fully Automatic IBC tank&Cage Production Line for U.S. Client

Client Background

Industry: Industrial Packaging

Location: Texas, USA

Business Type: OEM Manufacturer of IBC Tanks

Monthly Output: Over 5,000 units

Project Goal: Fully automate IBC cage  production to reduce labor costs and increase production efficiency

Project Overview

This client was originally a local IBC tank refurbishment company, focusing on recycling and reconditioning used IBCs. With the introduction of Xinzhou’s fully automatic IBC production line, they have now expanded into large-scale manufacturing of brand-new IBC tanks.

Our Solution: Fully Automatic IBC Cage Production Line

We provided a complete end-to-end automation solution—from raw material loading to final cage output.

1. Automatic Pipe Loading System

Key Features:

• Automatic pipe loading from storage racks

• Servo-controlled automatic feeding

• Accuracy: ±0.5mm

• Feeding speed: up to 20 pipes/min

Fully unmanned operation—just one operator can manage the entire section efficiently.

2. Fully Automatic Cage Welding Machine

Key Features:

• Automatic positioning of vertical and horizontal pipes

• Dual-layer double-station welding platform allows continuous operation without downtime

Stable welding quality with minimal spatter. Welding strength meets U.S. DOT standards.

Full IBC Tank Production Workflow

1. Cage Process:

Frame welding → Pipe bending → Riveting → Punching → Frame output →

Metal base frame welding → Base auto ejection → Bottom plate loading →

2.  Manual screw fixing of cage and baseInner Tank Process:

Inner tank conveying → Automatic valve installation (screw-on or welded) →

Automated leak testing → Tank mounting into cage →

Manual installation of tie rods → Final palletizing of finished IBCs

On-Site Engineering Support

After project launch, Ningbo Xinzhou dispatched several senior engineers to the U.S. site to provide comprehensive technical support, including:

• Installation & Commissioning: Complete on-site setup, leveling, wiring, PLC configuration, and trial run

• Operator Training: 1-on-1 technical training for the client’s team, including programming, routine maintenance, and troubleshooting

• Process Optimization: Welding parameter fine-tuning and production cycle optimization based on actual factory conditions

• Remote Support: VPN-enabled remote diagnostics and real-time tech support after setup

No guesswork, no hassle—this is a full turnkey solution. Plug in and start producing!

Customer Feedback

“The automation level was far beyond our expectations. Clean welds, massive labor savings, and the Xinzhou team handled installation like seasoned pros. A very smooth cooperation.”

— Operations Manager, U.S. Packaging Factory

Why Choose Ningbo Xinzhou?

• 20+ years of welding automation experience

• Customizable layout tailored to your factory space

• Free on-site installation & training + remote tech support

• CE certified, ISO9001-compliant manufacturing facility

Looking to Upgrade Your IBC Cage Production Line?

Get in touch today for a customized solution and quote that fits your production goals.

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