LAF Flexitank Installation & Removal Guide
How Flexitank Systems Are Installed, Loaded, Sampled, Discharged, Removed, and Recycled
A complete operational guide based on LAF Flexitank installation procedures, covering container selection, preparation, flexitank fitting, bulkhead installation, loading, sampling, discharge, removal, and responsible disposal for safe bulk liquid transportation.
Why Proper Flexitank Installation Is Critical
A flexitank transforms a standard 20-foot shipping container into an efficient bulk liquid transportation system. However, safe performance depends not only on the flexitank itself, but also on proper container selection, interior preparation, liner positioning, bulkhead support, controlled loading, careful discharge, and responsible recycling after use.
A fully loaded flexitank can contain more than 20 tonnes of liquid cargo. During transport, the cargo is exposed to container handling, road movement, braking, turning, lifting, vessel motion, and other dynamic forces. These forces place pressure on the flexitank, the bulkhead, and the container structure.
Poor installation can increase the risk of cargo leakage, contamination, container damage, transport delay, product loss, and operational safety hazards. Correct installation helps protect cargo quality, container integrity, transport safety, and customer confidence throughout the logistics chain.
Step 1
Container Selection and Criteria Check
Before installation begins, the 20-foot standard container must be carefully inspected to confirm that it is suitable for flexitank use and capable of meeting international shipping safety expectations.
Payload & Age
The container nameplate should specify a maximum rated payload of 30,000 kg (67,000 lbs). The container should not be more than 5 years old and must be in good condition.
Structural Integrity
External panels must be free from previous structural repairs. Each container door must have two fully workable locking bars and a distinct vertical groove.
Cleanliness & Safety
The interior must be dry, clean, and free from debris, sharp edges, floor splinters, loose screws, dents, or protruding welds that could puncture the liner.
Contamination Check
Interior panels and the floor must be free from transferable stains, odors, or pollution sources that could react with or leach into the liquid cargo.
Documentation
The operator should complete and sign the Flexitank Fitting Checklist for quality tracing and operational record purposes.
Step 2
Cargo Loading Preparation and Protective Lining
Once the container passes inspection, the interior must be lined with protective materials to defend the flexitank from friction, abrasion, and contact with rough container surfaces.
Final Floor Cleaning
Clean the container floor one final time to ensure that no debris remains. Even small fragments can create pressure points after loading.
Lay Corrugated Paper
Roll out and lay the corrugated paper across the container floor to provide a protective cushioning layer beneath the flexitank.
Secure and Cover Friction Points
Secure the paper firmly to the floor, side walls, and front-end joint area using heavy-duty adhesive tape. Ensure all sharp corners and possible friction points are completely covered.
Step 3
Flexitank Positioning and Unfolding
Proper alignment prevents uneven stress distribution on the liner walls during filling. The flexitank must be placed, unfolded, and centred carefully before the bulkhead framework is installed.
Careful Removal
Remove the flexitank carefully from its shipping carton without dragging or damaging the liner.
Lengthwise Unfolding
Unfold the liner lengthwise toward the front end of the container.
Sideways Unfolding
After extending it lengthwise, unfold the liner sideways toward the left wall.
Centreline Alignment
Align the central line of the flexitank precisely with the central line of the container.
Important Door-End Clearance
At the door end, fold the flexitank inward so it sits approximately 50 cm away from the container doors. This leaves sufficient clearance space to mount the bulkhead framework safely and correctly.
Step 4
Bulkhead Installation Options
The bulkhead is one of the most important safety components in a flexitank installation. It supports the loaded flexitank at the container door end and prevents direct liquid pressure from acting on the container doors.
Depending on the specific kit supplied, the operator should install the corresponding bulkhead configuration. The following options are commonly used in the LAF Flexitank installation procedure.
Bulkhead Type A
Cardboard Panel + Steel Bar System
This configuration uses a reinforced cardboard panel supported by adjustable steel bars. It provides a strong barrier between the loaded flexitank and the container doors while remaining lightweight and easy to install.
- Fit the main cardboard piece flat against the rear opening.
- Insert the adjustable steel bar into the door-post grooves and tighten the securing bolt.
- Position and mount the remaining horizontal steel bars one by one.
- Insert protective paper tubes vertically between each set of horizontal bars.
- Secure the steel bars to the cardboard using cable ties through the pre-drilled holes.
- Install the vertical stabilizing steel bar and secure it using the same method.
- Pull the flexitank bottom valve through the dedicated opening in the cardboard panel.
- Fasten the valve securely to the framework using cable ties.
- Verify that the valve handle points precisely to the 12 o’clock position.
Bulkhead Type B
PP Board + Rigid Frame System
This configuration uses a heavy-duty polypropylene board supported by a rigid steel frame. The design provides excellent structural stability while maintaining straightforward installation procedures.
- Position the polypropylene board across the door opening.
- Insert the primary rigid steel frame into the container grooves.
- Tighten the alignment bolts securely.
- Install the remaining horizontal steel bars sequentially.
- Secure the bars tightly to the PP board using cable ties through the pre-drilled holes.
- Insert protective paper spacer tubes between every two horizontal bars.
- Fix the vertical support bar to the board using cable ties.
- Pull the bottom valve through the PP board opening.
- Secure the valve using cable ties and maintain the handle at the 12 o’clock position.
Bulkhead Type C
PP Board + Dual Rigid Frame System
This configuration utilizes separate upper and lower rigid frames to provide additional structural reinforcement at the container door end.
- Position the PP board across the door frame.
- Slide the lower rigid steel frame into the container grooves.
- Tighten the fixing bolts securely.
- Install the upper rigid frame directly above the lower frame.
- Secure both frames firmly to the PP board using cable ties through the pre-drilled holes.
- Route the bottom valve through the designated opening.
- Anchor the valve body securely using cable ties.
- Verify that the valve handle remains firmly positioned at the 12 o’clock position.
Door Security Configuration (Applicable to All Bulkhead Types)
After the valve has been secured, the container’s left-hand door must be closed completely.
Attach the official warning label to the outside of the left-hand door and hang the warning tag directly on the left-hand door latch.
This safety procedure is critical because it helps prevent accidental opening of the wrong door after the flexitank has been loaded. A loaded flexitank can exert substantial pressure on the door area, making proper door management an essential operational safety requirement.
Step 5
Cargo Loading Operations
During loading operations, the left-hand door must remain closed at all times. Loading takes place entirely through the open right-hand door.
Connect the Loading Hose
Remove the protective valve caps. Inspect the valve opening for dirt or contamination. Connect the loading hose securely to the valve assembly.
Begin Pumping Operations
Open the valve and start the pump. Transfer liquid cargo into the flexitank while continuously monitoring filling progress and cargo volume.
Monitor Filling Volume
Continue loading until the flexitank reaches its approved and designated volume payload. Operators should monitor the operation closely throughout the filling process.
Secure the Valve
Immediately stop the pump upon reaching the required filling volume. Close the valve completely, disconnect the loading hose, and reinstall the protective valve caps.
Container Closure
Close and secure the right-hand door. Install a high-security bolt seal and apply all required warning or cargo identification labels to the container exterior.
Step 6
Sampling Procedure (If Required)
Some cargoes require product sampling at destination before complete discharge begins. Sampling should be carried out carefully to prevent contamination and preserve cargo integrity.
- Verify that the container door seal remains intact and shows no signs of tampering during transit.
- Keep the left-hand door closed and open only the right-hand door.
- Remove the outer valve cap and inspect the valve opening for dirt or foreign material.
- Mount the designated sampling cap securely onto the valve threads.
- Open the valve slowly and allow product to flow safely into the sampling bottle.
- Once sampling is complete, close the valve immediately and reinstall all protective caps.
Step 7
Discharging and Flexitank Removal Procedures
Upon arrival at the receiving facility, discharge operations should be carried out carefully by trained personnel using suitable pumping equipment. Proper discharge procedures help maximize product recovery, reduce operational risks, and prevent damage to the flexitank system.
Initial Inspection
Keep the left-hand door closed and open only the right-hand door. Inspect the valve opening and remove any dirt or debris before connecting the discharge hose.
Connect the Discharge Hose
Connect the discharge hose carefully. The hose should remain parallel to the valve throughout the operation to prevent bending stress on the valve neck.
Begin Product Discharge
Start the discharge pump and begin draining the liquid cargo. As product leaves the flexitank, the liner will gradually collapse.
Reduce Flow Rate
When the upper surface of the collapsing liner reaches approximately 15 cm above the floor, reduce the discharge rate to approximately 300 litres per minute.
Prevent Cavitation
Reducing the flow rate helps prevent pump cavitation and minimizes the possibility of the liner being pulled against the discharge outlet.
Stop Pumping
Once liquid stops flowing naturally, stop the pump and disconnect the discharge hose.
Bulkhead Removal
After discharge is completed, open both container doors fully. Carefully dismantle and remove the bulkhead boards, paper tubes, steel bars, and supporting framework components.
Residual Product Recovery
After normal discharge operations have finished, some residual liquid may remain inside the liner. Product recovery procedures help maximize cargo utilization and minimize waste.
Operators may enter the container, following all applicable site safety requirements and confined-space procedures where relevant.
The empty flexitank should then be rolled carefully from the rear wall of the container toward the valve end.
This action helps push any remaining liquid residue toward the discharge outlet, allowing additional product to be recovered.
After all recoverable product has been removed, the empty flexitank can be lifted from the container and transferred to the designated disposal or recycling area.
Step 8
Disposal and Environmental Recycling
Once operations are complete, all materials should be removed from the container and processed according to local environmental regulations and company waste management procedures.
Flexitank Liner
Used liners may be sent to authorized waste disposal facilities for controlled disposal according to local regulations.
Where recycling programs are available, liners can be rolled, sorted, and delivered to specialized plastics recycling facilities for material recovery and classification.
Bulkhead Components
Cardboard panels, paper tubes, steel bars, and other structural components should be separated according to material type.
Whenever possible, these materials should be delivered to authorized recycling centres for reuse and processing.
Common Flexitank Installation Mistakes to Avoid
Flexitank Installation and Removal Checklist
Frequently Asked Questions
Why must the left-hand door remain closed?
The left-hand door remains closed to reduce the risk of accidental opening after loading. A loaded flexitank exerts significant pressure toward the door end of the container.
Why should the valve handle remain at the 12 o’clock position?
The specified orientation helps ensure correct valve positioning and consistent operational procedures during loading and discharge.
Why is corrugated paper installed on the container floor?
Corrugated paper helps reduce friction, cushions the liner, and protects the flexitank from abrasion against container surfaces.
Why is discharge flow reduced to 300 litres per minute?
Reducing flow during final discharge helps prevent pump cavitation and reduces the risk of the liner being pulled against the outlet.
Need Professional Flexitank Installation Support?
LAF Flexitank Services provides flexitank supply, installation, loading supervision, discharge support, technical guidance, and bulk liquid transportation solutions throughout Malaysia.
Our experienced team can assist with project planning, site operations, cargo compatibility assessments, and operational best practices for safe and efficient bulk liquid logistics.
Contact us today to discuss your flexitank requirements and bulk liquid shipping needs.