01 / TIMELINE
Orbit by orbit
The long version
2009
Two totes and a pressure washer
Desmond Ayer buys 40 condemned IBC totes from a shuttered Anderson adhesives plant for $12 each, washes them in a rented bay off Brookville Road, and sells 38 of them to a landscape supply yard within a month. The other two are still on site — they hold wash chemistry today and have never left the property.
2011
The first real wash line
A four-station line goes in: pre-rinse, caustic soak, hot rinse, dry. Throughput jumps from nine units a day to fifty-two. We also learn our first hard lesson about prior cargo and stop accepting anything without a cargo declaration — a rule that has never been relaxed since.
2013
Grading becomes a written system
Customers kept asking what 'good condition' meant. So we wrote it down: nineteen inspection points, three grades, one card per tote. The A-to-C scale published on our size guide is a direct descendant of that first laminated sheet.
2015
Shadeland Avenue
We move to 3201 N Shadeland Ave — 46,000 square feet, four dock doors, and enough paved yard to stage 2,000 units. The building was a truck body shop, which is why the fabrication bay has a 12-ton overhead crane we did not have to install.
2017
Water reclaim skid goes online
A three-stage reclaim skid — settling, bag filtration, carbon polish — cuts municipal water draw by roughly two thirds. Our wash water recycling rate hits 71% in year one and sits at 86% today. This single project remains the biggest environmental win in company history.
2019
Rebottling and UN re-marking
We start dropping new HDPE bottles into reclaimed cages at volume, and earn the ability to re-mark units to UN 31HA1/Y specification after test. A ten-year-old cage with a new bottle leaves the yard carrying hazmat again — which is a very good day for everybody.
2021
Resin recovery, in house
A granulator and wash-float tank let us stop selling scrap bottles by the trailer and start selling clean HDPE regrind by the gaylord. Diversion rate crosses 97% for the first time. The 0.6% we still cannot divert is mostly contaminated gasket rubber and pallet nails.
2023
The upcycle bay
Eleven standard build patterns — rain harvest kits, planter walls, aquaponic beds, jobsite wash stations — come out of a bay that used to be overflow storage. Totes too tired for cargo find a second career holding rainwater in somebody's back garden.
2024
99.4%
Our best year on diversion, and the year we published our full carbon method rather than a vague claim. 21,400 units handled, 41 million pounds of CO₂e avoided against the new-tote baseline, zero landfill tickets for the bottle stream.
2026
Pooling, and the boring future
Leasing and tote pooling is now a third of revenue. The honest goal for the rest of the decade is unglamorous: more loops per container, fewer empty miles per load, and a wash cycle under nine gallons.
Three things we got wrong
A history page that only lists wins is a brochure. These are the decisions that cost us real money, and what they taught the yard.
We once trusted a verbal cargo history
In 2010 a batch of twelve totes arrived described as “just soap.” It was a cationic surfactant blend that pitted the gaskets and left an odour no wash cycle would lift. All twelve went to resin recovery. Since then: no written cargo declaration, no purchase. It costs us a few deals a month and it has never once been the wrong rule.
We under-built the first reclaim skid
The 2017 skid was sized for the throughput we had, not the throughput we wanted. Eighteen months later we replaced the filtration stage entirely. If you are building water reclaim, size it for triple your current volume — the incremental cost is small and the retrofit cost is not.
We sold on grade before we could prove grade
Early on, “Grade A” meant whoever loaded the truck liked the look of it. Two disputed loads in 2012 taught us that a grade without a written record is just an opinion with a price tag. The nineteen-point inspection exists because of those two loads.
E / GRADING
A grade is a promise, not a mood
How every unit is scored
| # | Point | Critical? |
|---|---|---|
| 01 | Prior cargo declaration — present, written, specific | Yes |
| 02 | Residual liquid — any volume at all | Yes |
| 03 | Odour after wash — fixed odour by trained nose | Yes |
| 04 | Bottle corner stress whitening | No |
| 05 | Interior scoring you can feel | No |
| 06 | Interior crazing — fine surface cracking | Yes |
| 07 | Bottle bulge or deformation | Yes |
| 08 | Wall thickness at the thinnest point | Yes |
| 09 | Dome port condition and flange flatness | No |
| 10 | Outlet threads — cross-threading, chipping | Yes if crossed |
| 11 | Valve function, full open and close | No, replaceable |
| 12 | Gasket condition — compression set, bloom | No, replaceable |
| 13 | Cage squareness along the top rail | No, pressable |
| 14 | Cage weld integrity at tube intersections | Yes |
| 15 | Cage coating and galvanising loss | No |
| 16 | Pallet condition — cracked feet, rot, corrosion | No, replaceable |
| 17 | Forklift pocket integrity | No |
| 18 | UN marking legibility and date | No, re-markable |
| 19 | Leak test under our procedure | Yes |
F / END OF LIFE
Reuse first, recycle last
What happens when the container is finally finished
| Step | Outcome | Share of mass | Cost to us |
|---|---|---|---|
| 01 | Reuse as is — wash and redeploy | 63.9% | 11 gal of mostly reclaimed water |
| 02 | Repair and reuse — valve, gasket, pallet, cage | 11.4% | Parts and bench time |
| 03 | Rebottle — new bottle, reclaimed steel | 9.6% | A new bottle, two thirds of mass retained |
| 04 | Upcycle — rain kits, grow beds, wash stations | 3.2% | Fabrication time |
| 05 | Material recovery — HDPE regrind, steel, wood | 11.3% | Grinding, washing, drying energy |
| 06 | Residual to licensed disposal | 0.6% | Sludge, gasket rubber, fasteners, laminates |
D / ORDERING
Commercial terms, up front
Lead times, minimums and what happens when it goes wrong
| Item | Detail |
|---|---|
| Minimum order | One unit. No account minimum, no membership. |
| Stock lead time | Grade A and B 275 gal usually ship the same week |
| Rebottled lead time | 2–3 weeks, built to order in bay D |
| Food-grade lead time | 1–3 weeks when stock exists; supply-dependent |
| Full truckload | 45 on a 48 ft flat, 48 in a 53 ft van, 90 empties double-stacked |
| Payment, first order | Prepay by ACH or card |
| Payment, established | Net 30 on credit approval |
| Grade guarantee | Regrade or replace, our freight both ways, 14 days |
| Leak warranty | 30 days from delivery, normal atmospheric service |
| Cancellation | Free until the truck is loaded |
| Returns | 14 days on unused stock units, freight at your cost |
| Sales tax | Indiana resale certificates and out-of-state equivalents accepted |
A / SPECIFICATION
Reference
Dimensions, fittings and seat materials
Fig. 1
Fig. 2| Capacity | Litres | Footprint | Height | Tare | Gross (water) | Stack loaded |
|---|---|---|---|---|---|---|
| 275 gal | 1,041 | 48 × 40 in | 46 in | ≈140 lb | ≈2,435 lb | 2 high |
| 330 gal | 1,249 | 48 × 40 in | 53 in | ≈155 lb | ≈2,905 lb | 2 high |
| 350 gal | 1,325 | 48 × 40 in | 56 in | ≈165 lb | ≈3,075 lb | 2 high |
| 120 gal | 454 | 40 × 32 in | 38 in | ≈95 lb | ≈1,095 lb | 2 high |
| 180 gal | 681 | 42 × 36 in | 42 in | ≈115 lb | ≈1,616 lb | 2 high |
| 550 gal | 2,082 | 60 × 48 in | 60 in | ≈240 lb | ≈4,830 lb | 1 high |
B / FITTINGS
What threads onto it
Fittings, threads and seat materials
| Fitting | Size | Seals by | Seat options | Typical service |
|---|---|---|---|---|
| S60x6 butterfly valve | 2 in | Flat gasket face | EPDM, Viton, PTFE | The standard IBC outlet |
| S70x6 butterfly valve | 2 in | Flat gasket face | EPDM, Viton | European and some 330 gal units |
| 2 in NPT ball valve, poly | 2 in | Thread flanks + tape | EPDM, Viton | Retrofits, metered dispensing |
| 2 in NPT ball valve, stainless | 2 in | Thread flanks + tape | PTFE | Solvents, pressure, hot cargo |
| 3 in butterfly valve | 3 in | Flat gasket face | EPDM, Viton | Viscous cargo, high flow |
| 6 in fill cap | 6 in | Gasketed lid | EPDM, silicone | Vented or solid — choose deliberately |
| Camlock adapter, type C | 1.5 / 2 in | Cam arms + gasket | Buna, Viton | Repeated connect / disconnect |
| Bulkhead tap | 3/4 in | Both-side gaskets | Brass, poly | Rain kits, site water |
| Material | Good with | Avoid with | Temperature | Cost |
|---|---|---|---|---|
| EPDM | Water, acids, caustics, brine, ag-chem | Oils, fuels, aromatics | -40 to 250 °F | Low |
| Viton (FKM) | Solvents, oils, fuels, aromatics | Ketones, amines, hot steam | -15 to 400 °F | High |
| Nitrile (NBR) | Oils, diesel, greases, hydraulics | Ozone, strong oxidisers | -30 to 250 °F | Low |
| PTFE envelope | Almost all chemistry, high purity | Needs very flat flange faces | -100 to 450 °F | High |
| Silicone | Food contact, wide temperature | Solvents, abrasion | -60 to 450 °F | Medium |
C / COMPATIBILITY
Will HDPE hold it?
Sixteen cargo families, rated
| Cargo family | HDPE | Seat | Notes |
|---|---|---|---|
| Water, potable and non-potable | A | EPDM / silicone | Food-history units for potable |
| Acids and caustics, aqueous | A | EPDM / PTFE | Vent fuming cargo |
| Liquid fertiliser, UAN, NPK | A | EPDM | SG up to 1.32 — check your lift-gate |
| Brine and chloride de-icer | A | EPDM | Hard on galvanising, kind to HDPE |
| Food syrups, oils, concentrates | A | Silicone / Viton | Documented food history only |
| Glycols | A | EPDM | Very common; SG 1.04–1.11 |
| Alcohols | A | Viton / PTFE | Flammable — bond and vent |
| Diesel and gas oil | B | Viton / NBR | Permeates slowly over long storage |
| Mineral spirits | B | Viton | Swells HDPE slowly |
| Surfactants and detergents | B | EPDM | Odour fixation risk — dedicate units |
| Latex, adhesives, water-based paint | A | EPDM | Cures if left. Wash promptly. |
| Ketones, aromatics, chlorinated solvents | C | — | Crazes HDPE. Stainless only. |
| Gasoline and low-conductivity fuels | C | — | Static risk. Steel or stainless. |
| Essential oils, flavour concentrates | C | — | Fixes into the wall permanently. Never. |
| Hydrogen peroxide above 10% | C | — | Decomposition and pressure risk |
| Dairy and hot-fill above 140 °F | C | — | Needs CIP and steam. Stainless. |
Permeation
Small non-polar molecules pass slowly through HDPE rather than attacking it. The bottle looks perfect and your cargo quietly leaves. It is a storage-duration problem: diesel for a week is fine, diesel for a year is not.
Crazing
Ketones, aromatics and chlorinated solvents cause fine surface cracking that propagates under stress. It is invisible until you hold the wall against a raking light, and it is a critical grading failure.
Odour fixation
Terpenes and some surfactants dissolve into the polymer itself rather than sitting on the surface. No wash removes them. This is why a food-grade tote has to have been a food tote from new.
G / PITFALLS
Learned the expensive way
Five mistakes that cost people money
Ordering a 330 without measuring the ceiling
A 275 and a 330 share a footprint; the 330 is seven inches taller. Two 330s stacked is 110 inches against 96 for two 275s, and most sprinkler regimes want eighteen inches of clearance below the deflector. That seven inches is frequently the whole margin.
Forcing an NPT fitting into an S60x6 port
Both are roughly two inches, so it bites and feels tight. It is not sealing, it is chewing the buttress thread. The joint weeps two days later, usually in transit, and cross-threading is one of the few faults that condemns an otherwise perfect bottle.
Reusing a flange gasket
A gasket is a one-use part the moment it has taken a compression set. Reusing one is the cause of most 'the new valve still leaks' emails we get. They cost a couple of dollars. Keep a box at the fill point.
Specifying a solid lid on a tote that sees sun
Sealed container, rising temperature, nowhere for the expansion to go. The bottle bulges between the cage bars and does not fully return. A vented lid is the cheapest risk control in this industry.
Ignoring specific gravity
A full 275 of water is 2,435 lb. The same tote of UAN 32 is 3,168 lb, and a 330 is 3,785 lb. Plenty of lift-gates are rated at 2,500 or 3,000 lb, and the rating assumes a centred load.
Seventeen years in