Fully Automatic IBC Tank Production Line Project in USA And Spain | Turnkey IBC Cage & Blow Molding Solution

Turnkey IBC Blow Molding and IBC Cage Manufacturing Solution

With the rapid global growth in demand for bulk liquid packaging, Intermediate Bulk Containers (IBCs) are becoming the preferred solution for industries such as chemicals, food additives, pharmaceuticals, and industrial liquids. To meet the increasing requirements for automation, production efficiency, labor cost reduction, and workplace safety, Ningbo Xinzhou Welding Equipment Co., Ltd. successfully delivered fully automatic IBC tank production lines to customers in both the United States and Spain.

These projects represent modern smart manufacturing for IBC production, integrating IBC blow molding, automatic trimming, robotic handling, cage frame welding, and automatic assembly into one seamless system.

Project Background

USA Project – Upgrading to Full Automation

The American customer supplies IBC tanks to local chemical companies. Their previous semi-automatic setup faced several challenges:

• High labor costs

• Inconsistent production rhythm

• Safety risks from manual handling of hot plastic inner bottles

Their goal was clear:
 Build a fully automatic IBC tank production line to achieve stable, high-volume output with minimal labor involvement.

Spain Project – Building a Smart IBC Factory from Scratch

The Spanish customer already had experience in metal packaging and wanted to enter the IBC market with a highly automated production model from day one. Their priorities included:

• Advanced automation level

• Consistent product quality

• Reduced human intervention

• Compliance with strict European safety standards

Fully Automatic IBC Tank Blow Molding Line

Ningbo Xinzhou provided a complete IBC inner bottle (liner) manufacturing system with end-to-end automation.

Key Automated Processes

1.Automatic Material Feeding

Raw materials are automatically conveyed to the blow molding machine through a centralized feeding system, improving cleanliness and ensuring stable production.

2. Heavy-Duty IBC Blow Molding Machine

• Stable parison control

• Uniform wall thickness

• Reduced material waste

• High repeatability for consistent bottle quality

3. Automatic Trimming System

After molding, excess material is removed automatically, ensuring precise dimensions and eliminating manual rework.

4. Robotic Take-Out System

Industrial robots automatically remove the hot IBC inner bottle, avoiding dangerous manual handling and significantly improving worker safety.

5. Automatic Transfer to IBC Cage Line

Finished plastic liners are conveyed directly to the cage assembly line, enabling automatic connection between plastic and metal production processes.

 Result: The entire blow molding section operates with minimal human intervention, reducing labor intensity and burn risks.

Fully Automatic IBC Cage Production Line

The IBC cage manufacturing system is one of the most technically complex parts of the project. Xinzhou designed a highly integrated automatic cage production line.

Main Automation Units

1. Automatic Feeding of Long and Short Tubes

Different steel tube specifications are automatically fed into the system, reducing manual handling and improving positioning accuracy.

2. Automatic Welding System

• Automatic mesh welding

• Uniform weld strength

• Much higher speed compared to manual welding

3. Automatic Bending System

Welded mesh panels are automatically bent into the IBC cage shape with precise and consistent dimensions.

4.Automatic Locking and Punching

Critical structural features are processed automatically, ensuring reliable connections and eliminating manual fitting errors.

5. Automatic Steel Pallet Welding Line

IBC steel bases are welded in automated stations, ensuring consistent load-bearing performance.

Automatic Assembly of IBC Cage and Plastic Inner Bottle

One of the biggest highlights of these projects is the fully automatic cage and liner assembly system.

After the plastic inner bottle arrives from the blow molding line:

• Automatic positioning ensures accurate alignment

• The system completes cage and bottle assembly without manual lifting

• Workers no longer need to manually insert heavy liners into metal cages

 Traditional assembly requires multiple workers and involves safety risks.
 Now, automation improves both efficiency and workplace safety.

Key Benefits Achieved by the Customers

 Significant Labor Cost Reduction

The production line now requires only a small team for supervision and material supply — labor demand reduced by more than 50%.

Improved Production Safety

• No manual handling of hot blow-molded bottles

• Reduced heavy lifting of steel cages

• Lower workplace injury risk

 Stable and Predictable Output

Automated rhythm ensures consistent cycle times, helping customers better manage delivery schedules.

 Higher Product Consistency

Automatic welding, bending, and assembly guarantee uniform cage dimensions and structural strength.

Xinzhou’s Turnkey IBC Production Line Capability

As a professional IBC production line solution provider,
Ningbo Xinzhou Welding Equipment Co., Ltd. offers more than individual machines:

• IBC blow molding machines

• Fully automatic IBC cage production lines

• Integrated conveying and automation systems

• Support for IBC raw materials and components

• Complete factory layout and smart manufacturing planning

We help customers build not just equipment, but a high-efficiency, safe, and future-ready IBC manufacturing plant.