What Components Make Up a Complete IBC Tank? A Step-by-Step Structural Overview

Discover all the key components of a complete IBC tank, from metal cage mesh and base structure to plastic inner tank, valve, lid, and protective accessories.

What Is a Complete IBC Tank Made Of?

An Intermediate Bulk Container (IBC) is not a single product, but a carefully engineered system composed of multiple structural and functional components.
Each part plays a critical role in strength, safety, durability, and transport performance.

Below is a detailed, step-by-step explanation of all main components that form a complete IBC tank, following the actual manufacturing and assembly process used in modern IBC production lines.

1. Metal Wire Mesh Panel – The Foundation of the IBC Cage
   

The production of an IBC cage starts with a welded metal wire mesh panel, manufactured on an automatic cage welding line.

Function

• Provides external mechanical protection

• Ensures stacking strength

• Maintains container shape during transport and storage

Key Features

• Precisely welded steel wires

• Uniform mesh spacing

• High welding consistency to avoid weak points

This metal mesh panel is the structural backbone of the IBC cage.

2. Cage Bending and Forming – Creating the IBC Frame

Once the mesh panel is completed, it is automatically bent into a square cage shape.

Process

• The flat mesh is bent at precise angles

• The head and tail ends are aligned and connected

• Dimensional accuracy is strictly controlled

Why It Matters

Accurate bending ensures:

• Perfect fit with the plastic inner tank

• Stable load distribution

• Uniform appearance across all IBC units

3. Punching & Flattening – Preparing the Cage Bottom Connection

After cage forming, the lower part of the cage goes through a punching and flattening process using a punching & flattening machine.

Purpose

• Remove specific bottom sections of the wire

• Create flat, connection-ready surfaces

• Prepare the cage for base assembly

Result

This process allows the cage to be securely connected to:

• Steel base pallets

• Plastic base pallets

• Wooden pallets (in some regions)

Without this step, stable base fixation would not be possible.

4. Base Structure – Steel, Plastic, or Wooden Pallet

The base (pallet) is a critical load-bearing component of the IBC tank.

Common Base Types

• Steel pallet: Highest strength and durability

• Plastic pallet: Lightweight and corrosion-resistant

• Wooden pallet: Cost-effective for specific markets

Function

• Supports full liquid load (up to 1000 liters)

• Enables forklift handling

• Ensures safe stacking and transport

5. Cage-to-Base Fixation – Mechanical Assembly with Bolts

The formed metal cage is mechanically fixed to the base using bolts and screws.

Why Bolted Assembly Is Important

• Strong and reliable connection

• Easy maintenance or replacement

• Compatible with different base types

This step finalizes the rigid outer structure of the IBC.

6. Corner Protectors – Preventing Friction and Wear

To prevent direct contact between the plastic tank and metal cage, plastic corner protectors are installed.

Benefits

• Reduces friction during transport

• Prevents abrasion and wear

• Extends the service life of the inner tank

• Improves overall safety

These small components play a big role in long-term durability.

7. Valve, Lid, and Baffle – Functional Accessories

A complete IBC tank is finished with essential functional components:

Valve

• Installed at the bottom of the inner tank

• Controls liquid discharge

• Available in different materials and standards

Lid (Top Cap)

• Seals the filling opening

• Prevents contamination and leakage

Baffle / Anti-Sloshing Plate

• Improves liquid stability

• Reduces movement during transport

• Enhances safety for liquid handling

Conclusion: A Complete IBC Tank Is a System, Not a Single Product

A fully assembled IBC tank includes:

1. Welded metal wire mesh panel

2. Bent and formed metal cage

3. Punching & flattening preparation

4. Steel / plastic / wooden base pallet

5. Bolted cage-to-base connection

6. HDPE plastic inner tank

7. Corner protectors

8. Valve, lid, and baffle

Each component must be precisely manufactured and perfectly integrated to ensure product quality, safety, and compliance with international standards.

Complete IBC Production Solutions from Ningbo Xinzhou Welding Equipment Co., Ltd.

Ningbo Xinzhou Welding Equipment Co., Ltd. provides complete IBC production line solutions, including:

• IBC cage welding production lines

• Cage bending, punching, and flattening systems

• Steel pallet welding lines

• IBC blow molding machines

• Raw material supply (wire, tubes, pallets)

• Valves, lids, corner protectors, and accessories

• Turnkey IBC factory solutions

From individual machines to full production lines, we help customers build stable, efficient, and scalable IBC manufacturing systems.