We are also focusing on developing new products that handle heat. We are strongly conscious of selling these new products overseas. This time, we developed an IBC heater that can be attached to IBC containers, which are widely used overseas to transport liquids, oils, and other materials, and can transport the contents without solidifying them. At first glance, it looks like a simple heater, but it is packed with unique ideas that enhance its practicality.
We will introduce our IBC heater, which has been developed in few cases in Japan and is likely to be particularly useful in Southeast Asia, along with its background.
Liquid storage and transportation, drums in Japan, IBC overseas
When we think of storing or transporting large amounts of liquid, we probably think of cylindrical drums. Although the background and history are unclear, drums have long been the standard container for storing liquids in Japan.
On the other hand, drums are not as common overseas as they are in Japan. Instead, polyethylene containers called IBCs are used. IBC is an abbreviation for Intermediate Bulk Container, and is also called IBC or bulk containers. They are rectangular and can hold 1 ton (1,000 liters) of liquid. They have a liquid inlet at the top and a discharge outlet at the bottom. There is a groove at the bottom where a lifting device can be inserted so that they can be transported with a forklift or hand lifter, and they can be easily lined up or stacked on the floor.
Example of IBC (owned by our company)
IBCs are sold domestically and can be easily obtained, both new and used. Sizes vary slightly depending on the product specifications, but a typical 1,000-liter container is about 1 meter wide, 1.15 meters high, and 1.2 meters deep.
There is no reliable IBC heater that can transport liquids and oils without solidifying them.
IBCs are primarily used to store raw materials and pharmaceuticals, as well as to serve as containers for importing goods from overseas by ship. Items that can be stored include chemicals, pesticides, and food-grade oils and fats.
There are some important points to keep in mind when transporting IBCs by ship. The contents inside the container must remain liquid during transport to prevent solidification. When transporting by container ship, depending on the route, there are cases where the waters may reach below freezing. If the contents solidify during this time, it will be difficult to remove the liquid from the discharge port after arrival. Not only that, but there is also a risk that the quality will deteriorate due to solidification. Furthermore, if the discharge port is frozen, you may be forced to thaw the contents.
To prevent this from happening, it is necessary to heat the inside of the IBC container by attaching a heater to the side of the container before transport. This method involves turning on the heater to heat the inside of the IBC before loading onto the ship. Then, when loading begins, the heater is turned off and the residual heat keeps the contents liquid. After the ship arrives at port and the IBCs are unloaded, the heater can be used to warm the IBCs again, if necessary, until they are ready for transport by vehicle.
* Basically, it is not possible to operate the heater during transportation on a ship. This is because it is difficult to secure a power source to operate the heater. Even if it is possible to secure a power source, the use of the power source must be avoided in consideration of the safe navigation of the ship.
A dedicated electric heater is generally used to heat IBCs. However, there are no reliable IBC heaters currently on the market. A representative IBC heater is made in Denmark, but it has problems such as being prone to breakage during use, making it less reliable in quality.
Japanese trading companies that import IBC heaters are plagued by this problem, and whenever they receive inquiries from customers who say their heaters can no longer be used due to a broken wire, they are faced with the time-consuming and labor-intensive process of repairing them and ordering new ones. A person in charge at the trading company says that it would be great if safe and secure IBC heaters were manufactured and sold in Japan. However, they are struggling because they cannot find any companies manufacturing IBC heaters in Japan.
Our company has a long history of manufacturing heater products and is focusing on sales overseas. When we received an offer from a trading company, we discussed the matter internally and decided to develop an IBC heater.
Removable flat plate heater for added convenience
Ready-made IBC heaters are strip-shaped jackets that are wrapped around the sides of the container. Strip heaters have the advantage of being lightweight, but the disadvantage is that they cannot be wrapped by one person. One person must hold one end of the heater, while the other wraps it around the IBC and secures it in place.
Strip Jacket Heater
Therefore, we have created flat heaters that can be attached to each side so that installation can be done by one person. IBCs originally have a metal lattice-like enclosure on the side. A hook is attached to the back so that the flat heater can be hung on this and fixed in place. This innovation allows one person to lift and install the flat heater, eliminating the hassle of having multiple people install it as with strip heaters.
Flat Heater
There is another reason why we adopted the flat-plate type. If a strip heater is broken somewhere inside, it cannot heat up. If it cannot be repaired and needs to be replaced, it will be an expense. In contrast, with the flat-plate type, it is only necessary to replace the broken flat-plate heater. If you ask an agency, you can get a replacement in a short time, and you can reduce expenses because you do not need to replace the entire unit.
This flat heater has a metal housing, so each side weighs about 10 kilograms. Therefore, to reduce weight, we developed a flat jacket heater that combines the best of both worlds: lightweight and easy to install, using the same synthetic chemical material as the existing strip heaters. It has the same side-mount structure as the flat heater, with the heater wire for heating and glass fiber for insulation placed inside a jacket made of synthetic chemical material. The flat jacket is attached to each side of the IBC with a hook, and the power supply cables are connected in series.
Installation of jacketed flat heater
Flat jacket heaters contain insulation to prevent heat loss to the outside. This not only increases heat retention, but also reduces power consumption required for heating.
Jacket type flat heater
We are currently preparing to sell two types of flat-type IBC heaters: one with a metal housing and one with a jacket. Please see the following PDF catalog for detailed specifications of the IBC heaters we have developed.
IBC Heater Product Catalog (PDF)
Developing new products that can be used overseas opens up new possibilities for heaters
For the past few years, we have been expanding the sales channels for our heater products overseas, mainly in Southeast Asia. As part of this, we have been participating in international exhibitions held in Thailand and Vietnam, focusing on sales.
Exhibiting at Manufacturing Expo 2024 held in Bangkok, Thailand
When I was negotiating with local people at the exhibition, I felt frustrated that the heater products that we currently manufacture and sell do not meet their needs or are not accepted overseas. For example, hot water heaters are widely used in manufacturing sites in Thailand, and awareness of electric heaters such as silicone rubber heaters is low compared to Japan, so they did not show as much interest as I had hoped.
As we expand overseas, we wanted to create heater products that are more in demand at local factories. We thought this was the perfect opportunity to make that happen, so we created a unique heater that focuses on IBCs. Factories in Southeast Asia use IBCs to transport ingredients for processed foods and chemicals needed to manufacture industrial equipment, and there is a demand to prevent solidification during transport. The IBC heater we developed this time meets this demand, and we feel that we have finally been able to create a heater product that can be used overseas.
The IBC market size is also increasing. According to a survey and analysis by a market research company, the market is expected to grow by more than 4% from 2024 to 2029, five years from now.
We will be actively promoting IBC heaters at exhibitions both in Japan and overseas in the future. We are also considering selling them as a set with IBCs. If you would like to see the actual product right away, please come to our showroom, " DEN ." Our staff will be happy to explain the details to you.
