From Used to Like-New: Our Reconditioning Process
At Salt Lake IBC, reconditioning is not just washing out a tote and slapping on a new valve. It is a systematic, multi-stage process that transforms a used IBC into a container that meets or exceeds performance standards for its next life. We take pride in the quality of every tote that leaves our Woods Cross, Utah facility — because our reputation depends on it, and your operations depend on us.
In this article, we are pulling back the curtain on exactly what happens to an IBC from the moment it arrives at our yard to the moment it ships to you. Every step is designed to ensure safety, quality, and reliability.
Step 1: Intake and Sorting
Every IBC that arrives at our facility goes through an initial sorting process. We receive totes from a wide range of sources — chemical distributors, food processors, manufacturers, water treatment facilities, agricultural suppliers, and other businesses throughout the Intermountain West region. Each tote arrives with a different history, and that history determines what we can do with it.
During intake, our team records:
- Previous contents: Identified from labels, SDS sheets, and supplier documentation. This is critical because it determines whether the tote can be reconditioned for food-grade, general industrial, or specific chemical service.
- Manufacturer and date code: We note the original manufacturer (Schutz, Mauser, Greif, etc.), the year of manufacture, and the UN certification status.
- Visible condition: A quick visual scan for obvious damage — cracked bottles, severely bent cages, broken pallets, or contamination that would make the tote non-reconditionable.
Totes are then sorted into categories: food-grade candidates, general industrial candidates, totes that need rebottling (new bottle in the existing cage), and totes destined for material recycling (too damaged or too old to recondition economically). Approximately 80–85% of the totes we receive are suitable for reconditioning — a testament to the durability of modern IBC design.
Step 2: Residual Product Removal
Before cleaning can begin, any remaining product in the IBC must be safely removed. We drain residual liquids through the bottom valve into designated collection tanks, segregated by product type. Hazardous residuals are handled according to EPA and Utah DEQ regulations, with proper manifesting and disposal. Non-hazardous residuals are collected for recycling or treatment at licensed facilities.
This step is more important than it might seem. Even a small amount of incompatible residual left in the tote can contaminate the wash water, damage the wash system, or create a safety hazard. Our team is trained to identify residual products by color, odor, viscosity, and label information, and to handle each one appropriately.
Step 3: Disassembly
Next, we remove all serviceable components: the bottom valve, the fill cap, any gaskets, and the label plate or shrink wrap. These parts are inspected individually and either replaced (valves and gaskets are always replaced with new components) or cleaned and retained (the cap may be reused if it is in good condition).
Old labels and placards are completely removed. This is important both for accurate identification of the reconditioned tote and to prevent confusion about previous contents. We use a combination of scraping, steam, and solvent to ensure no label residue remains on the cage or bottle.
Step 4: The Triple-Wash Cleaning Process
This is the heart of our reconditioning operation. We use a triple-wash system that thoroughly cleans the interior of the HDPE bottle through three sequential stages:
Wash 1: Hot Alkaline Wash
The first wash uses hot water (140–160°F) with a commercial-grade alkaline detergent. High-pressure rotating spray heads are inserted through the fill opening, delivering the wash solution to every interior surface at pressures up to 1,500 PSI. The alkaline chemistry breaks down organic residues — oils, fats, surfactants, and biological material. This wash runs for approximately 3–5 minutes per tote, using 15–25 gallons of wash solution.
Wash 2: Acid Rinse (When Required)
For totes that held mineral-laden products, hard water chemicals, or anything that leaves inorganic scale, we follow the alkaline wash with a mild acid rinse (citric acid or phosphoric acid solution). This dissolves calcium, magnesium, and other mineral deposits that the alkaline wash cannot remove. Not every tote needs this step — we apply it based on the previous contents.
Wash 3: Clean Water Rinse and Sanitize
The final wash uses clean, hot potable water to rinse out all detergent and acid residues. For food-grade totes, we add a sanitizing step using an FDA-approved sanitizer at the appropriate concentration. The tote is then inverted or tilted to drain completely, and the interior is air-dried or dried with filtered compressed air.
Our wash water is collected, filtered, and treated in a closed-loop water treatment system that removes contaminants and allows us to recycle approximately 70% of our process water. This significantly reduces our water consumption and eliminates untreated wastewater discharge.
Step 5: Structural Inspection
After cleaning, every tote undergoes a thorough structural inspection:
- Bottle inspection: We check for cracks, crazing (fine stress lines in the HDPE), discoloration, odor retention, and wall thickness at critical points. Any bottle that shows signs of degradation is rejected for reconditioning — the cage and pallet may still be reused with a new bottle (rebottling), but the compromised bottle goes to HDPE recycling.
- Cage inspection: We examine every weld joint, check for bent or broken tubes, verify that the cage sits square on the pallet, and test the stacking lugs. Minor cage damage (small dents, surface rust) can be repaired. Structural damage (broken welds, severely bent corners) results in cage rejection.
- Pallet inspection: Steel pallets are checked for cracks, warping, and forklift tine damage. Wood pallets (less common) are checked for broken boards and nail protrusion. Plastic pallets are checked for cracks and deformation.
- Outlet spout inspection: The threaded outlet on the bottom of the bottle is inspected for cracks, cross-threading, and deformation. A damaged outlet means the tote cannot hold a valve securely — an immediate fail.
Step 6: Pressure Testing
For totes destined for liquid storage and transport, we perform a hydrostatic pressure test. The tote is sealed and pressurized with air to a level above the maximum expected operating pressure (typically 1.5–2.0 PSI for a standard atmospheric IBC). We then monitor for pressure drop over a defined period. Any tote that loses pressure — indicating a leak in the bottle, valve seat, or gasket area — is rejected or sent back for further diagnosis and repair.
Step 7: Reassembly with New Components
Every reconditioned IBC receives:
- A new bottom discharge valve — butterfly or ball, depending on customer specification or application requirements.
- A new outlet gasket — EPDM standard, with PTFE, Viton, or silicone available on request.
- A new or inspected fill cap with a fresh gasket.
- A dust cap on the valve outlet.
The valve is hand-tightened to the correct torque — snug enough to seal but not so tight that it cracks the HDPE outlet. We then perform a final leak check by filling the tote with a small amount of water, closing all openings, tipping the tote on its side, and verifying that no water escapes from any seal point.
Step 8: Grading and Labeling
We grade every reconditioned IBC on a quality scale that helps customers choose the right container for their needs:
- Grade A (Premium): Bottle is clean, bright white with minimal or no staining. Cage is straight with no visible damage. Pallet is in excellent condition. Suitable for food-grade or appearance-sensitive applications.
- Grade B (Standard): Bottle is clean with minor cosmetic staining or light discoloration that does not affect performance. Cage may have minor cosmetic imperfections. Fully functional for industrial applications.
- Grade C (Economy): Bottle is clean but shows visible staining or discoloration. Cage may have minor dents or surface rust (not structural). Best for non-critical storage, agricultural use, or repurposing projects.
Each tote receives a reconditioning label that identifies Salt Lake IBC as the reconditioner, the date of reconditioning, the grade, and a lot number for traceability.
Step 9: Final Quality Check and Storage
Before a reconditioned IBC moves to our ready-for-sale inventory, a final quality check verifies that all previous steps were completed, all new components are installed, the grading label is accurate, and the tote is clean inside and out. Approved totes are stored in our covered yard, organized by grade and size, ready for immediate pickup or delivery.
"Every tote that leaves our facility carries our name on it. That is why we never cut corners on cleaning, inspection, or components. Our customers trust us to deliver a container they can use with confidence, and we take that trust seriously." — Salt Lake IBC Team
If you would like to see our reconditioning process in person, we welcome visitors to our Woods Cross facility. Give us a call to schedule a tour — we are proud to show you how we work and answer any questions about the containers we produce.