Pioneering the Future of Bulk

Logistics in Asia

SOP FOR BULK DELIVERY

Table of Content

1) INSPECTION OF EMPTY CONTAINERS FOR LINER FITTING 2

2) PROCEDURES OF LINER FITTING 3
3) PRECAUTIONS DURING CONTAINER LOADING 5
4) CERTIFICATION OF DRIVER FOR DISCHARGING 7
5) PRECAUTIONS TAKEN AT DISCHARGING SITE 8
6) PROPER SETTING UP FOR DISCHARGING 9
7) PRECAUTION TAKEN DURING DISCHARGING 10
8) EMERGENCY RESPONSE AND COUNTER MEASURES 11
9) STORAGE AND MAINTENANCE 14

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 Pioneering the Future of Bulk
Logistics in Asia
Inspection of empty containers for
Liner fitting

On receiving instructions to collect an empty container, the UBC personal must check the
container for damage and certify that it is clean and there are no sharp debris on the container
floor. Items to look out for during the inspection of the containers are:

a) The exterior walls of the container should not be dented or have leaks in it.
b) The condition of the all the corners of the twist lock blocks must be good and not
corroded or dented
c) The floor of the container must be free of any sharp objects and must be check for any
wood splinters.
d) The latching of the door must be inspect to prevent any difficulty during the loading and
discharging of the product
e) The inner surface of the door must be inspected for any lengthy screw fasteners that
might puncture the liner when the door is closed after the loading.
f) The container must have 2 fully operational locking bars on each door
g) The container side panels must be free from jagged edges.
h) Before liner fitting, the container must be swept first.

Picture shows a damage container which should not be used for

loading

Picture shows damages of a container near the twist lock block.

Picture shows the container which is selected needs to be clean

and there are no sharp objects that might tear the liner during
fitting, loading and discharging.

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 Pioneering the Future of Bulk
Logistics in Asia

Procedure of Liner fitting

During the fitting process, these are the following guidelines that needed to be followed:

a) Bulkhead inspection before fitting.

- The bulkhead must be inspected for any tears or damage to ensure it provides a good
covering for the inner PE liner
- The joints of the webbings must be check to ensure that they are strong to prevent any
failure after loading and during discharging.
Bulk head should be spread out for inspection and webbings
should be screen for any loose ends joints.

b) Dry liner inspection.

- When the liner is taken out and spread across the floor, it should be examine throughout
to ensure there is no tear on the following areas:
● The venting sleeve especially adjoining the liner
● The discharging sleeve especially adjoining the liner
● The loading sleeve especially adjoining the liner
● The lashing points
● The whole surface of the liner
.
Liner must be spread out and inspected before fitting

c) Liner inspection after fitting

- A last physical check should be done to ensure that the liner is attached to the bulkhead
properly and there will not occur any stretching when product is loaded into it. Stretching
might cause the liner to tear.
- In order do so, these are the preventive procedures that must be followed to prevent
stretching.
● Upper webbing straps on the bulkhead panel at the top lashing point must be secured.
Picture shows the person incharge is checking the webbing is
fasten correctly at the top lashing points.

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 ● The steel bar is fitted correctly. The bottom steel bar is important to hold the amount of
product in place at the discharging sleeve. If the bottom steel bar is placed to high, taking out the
discharging sleeve will be a problem and sometimes applying extensive tugging force might
cause the liner to tear.
Bottom steel bar must be 400mm away from the floor.

Bottom steel bar

d) After fitting the liner and bulk head in place, the venting sleeve and loading sleeve must
be sealed to ensure no debris or insect might get into the liner.
e) Each liner fitting must have a dry liner fitting checklist to be filled in and filed with the liner
no, container no and job order. This dry bulk liner fitting checklist will keep record on the
date of fitting and each task done is distinctively noted down.
f) The container is the closed and trucked to the customer.

Diagram shows the dry bulk liner fitting checklist

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 Pioneering the Future of Bulk
Logistics in Asia
Precautions during container loading

During product loading, the following precautions should be taken every time as this would affect
the efficiency of discharging. During the loading operation, the supplier must ensure that the
blowing pipeline which directs the product into the liner does not have any openings or leaks
especially at areas where the pipeline has filtration points. Debris or insects might get caught up
at filters and will be sucked into the system and into the liner with the product.
The following precautions taken while loading are:

a) When the container has been trucked into the loading bay, the container doors must be
open to check the front portion of the liner and bulkhead. The opening of loading sleeve
and venting sleeve must check so see whether the seal is still intact.
b) The seals of both sleeves are released. The loading sleeve must be fitted onto the
loading gun and tie tight while the venting sleeve must be rolled backwards to prevent the
extension from flapping.
Picture shows loading sleeve tied tight at loading gun while
venting sleeve is fold back.

c) During loading, make sure that the loading gun is not inclined upwards. This might cause
the product flow to hit against the top portion of the liner. Constant bombardment of
product might cause a tear on the liner.
Picture shows tears on the top portion of the liner due do
resin flow directed to it during loading.

d) After the liner has been loaded, the venting sleeve and the loading sleeve must be seal
off with the customer seal.
e) Each loading is equipped with a dry bulk loading checklist. This check list will ensure that
the loading was done according to procedure and contamination would be prevented.
This check list must be filled and attached onto the bulkhead before the container door is
shut.

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Diagram shows the dry bulk liner loading checklist.

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 Pioneering the Future of Bulk
Logistics in Asia
Certification of Drivers for
discharging

UBC drivers are responsible for the cargo that they carry. They also take on the task of
discharging the product. Therefore, before a driver is left independent to do the discharging, he
must go through a certification process whereby he is evaluated with the following system.

Condition of certification
a) The certification of the drivers could only be done by a personal who himself has
already been certified by the proper authority which is currently UBC World Bulk
UK.
b) The driver has to be put through a series of discharging whereby he is there for
observation and practice with the assistance of a certified discharger.
c) When he is well verse with the requirements, he is then put through 3 evaluations
discharging where he needs to do the cleaning of the discharging accessories,
accessories set up and product discharging by himself.
d) The certified discharger will evaluated and certify the driver. There onwards, the
driver will be able to do the dischargings independently.

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 Pioneering the Future of Bulk
Logistics in Asia
Precautions taken at
discharging site

When the UBC operational personal or the driver who is in charge to handle the discharging at a
customer’s site enters for the first time, these are the following questions and observations that
he should ask and make in order to provide the proper service to the customer.

Questions post to the customer before discharging:

2) Which silo should be the material discharged into?

- This question should be posted to the customer and confirmed every time a discharge is
pre-executed. Discharging to the wrong silo, worst contaminating another product in the
wrongly discharge silo would result in loss in profit and degrading of service provider
reputation.

3) Is the power supply on or off?

- Check the power supply to see whether it is on or off. Make sure that it is off in order for
the handlers to connect the power cable. In that manner no accidences or death might be
caused due to negligence.

4) Is there a open/close valve in the silo pipe line? If so, is it open?

- This question is posted as a precaution to avoid any extensive wear and tear to the
pneumatic system. Some silos have internal control valves that might be shut to prevent
contamination in their material. Sometime, it would be a negligence issue for the
customer to open the valve for discharging. With a close valve, the pressure in the pipe
line would build up when the blower is turned on. With a high back pressure this would
definitely damage the blower.

Observations make before discharging:

1) Condition of discharging area.

- If there are foreign object which seems dangerous like sharp metal or wood, please
remove them from the site before any discharging is done.
- The floor level or the discharging platform must be flat in order for a safe discharge. This
is because, during tipping, the load on the axial of the tires should be distributed evenly. If
this is not so, the SDU might topple especially when the container is tilted at 45 degrees
due to high center gravity.

2) Caution taken when there is roofing at discharging site.

- The roofing of the discharging site must be at least 9 meters high in order to provide a
good discharge.

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 Pioneering the Future of Bulk
Logistics in Asia
Proper setting up for
discharging
When the chassis with the container on top arrives at the discharging site, these are the following
procedures that should be followed before starting the actual discharging.

a) Position the SDU at the best position for discharging. This should be emphasized
as it would contribute to the quality of discharging. The awkwardness of SDU
positioning would cause the conveying hose that connects the rotary valve to the
pipe line to be contorted, decreasing blowing rate.

b) Before the discharging accessories are set up, they should be clean preferably in
front of the customer to eliminate any doubts of contamination. Cleaning process
involves blowing using air pressure from the air gun supplied by the SDU
compressor. The following items that should be clean before discharging:

i) 4” hose c/w cam lock and adapter

ii) 10” flexible hose
iii) 3” plastic venting hose
iv) Tundish
v) TC frame
vi) Top plate
vii) 10” control valve
viii) O ring
ix) Rotary Valve

Cleaning the rotary valve:

Every time before a discharge is done the rotary valve must be check for any foreign material.
This is to prevent contamination of the material discharge and also prevent any damage to the
rotary valve. Cleaning can be done by blowing each pair of impellers a rotation through. Rotate
the impeller by hand after each blowing is done through.

Each impeller must be

blown clean before
discharging

Precaution: Make sure that the power supply is unplugged before any cleaning is done on
the rotary valve.

c) Make sure that all the twist locks on the chassis are fasten properly to the
container before any tipping is done.
After the cleaning process, we will proceed with fitting the discharging accessories onto the SDU

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 Pioneering the Future of Bulk
Logistics in Asia
Precaution taken during
discharging
With everything in place with the loading site at proper condition, the accessories have been
cleaned and set up on the SDU, the driver has to abide by the following procedures of
discharging.

a) Before the container door as open for discharging, there must be a customer
witness during the breaking of the container seal.
b) In some customer sites, a sample of the product has to be extracted and tested
before the discharging of that product lot can be started. Therefore under no
circumstances the driver is allowed to do the discharging before the green light is
given by the customer.
c) When the container is opened, the first thing the driver must check is the
condition of the bulkhead. Every lashing and steel bar must be intact and position
where they should be to prevent any complications during the discharging.
d) Purging the SDU system must be done after the discharging accessories are
connected to the liner.
Purging:-
Purging is a method whereby the internal piping system of the SDU is blown clear of
any debris.

Procedure of purging:-
- Before the 4” hose flexible hose is connected to the rotary valve, the SDU blower must be
started to blow out air through the rotary valve to clean both the piping system and the
rotary valve. During this process a venting bag is place onto the outlet of the rotary valve
to capture any foreign particles.
- Once this is done, on end of the 4” flexible hose can then be couple to the rotary valve
but no the silo. There will be a venting bag inserted at the other end of the 4” flexible hose
to capture any debris in the hose.
- A fraction of the product is let into the rotary valve to be blown into the venting bag to
ensure the interior of the hose is not block or hindered.

e) After purging is done, the discharging can now commence. During the
discharging, the driver must ensure that there is no tear in the liner that might
cause wastage or contamination.
f) After all the product have been emptied from the liner into the silo, the driver
must ensure that there are no product residue accumulated at the corners of the
liner, the back portion of the liner, the venting or discharging sleeve.
g) The discharging sleeve is then disconnected from the accessories and place
back into the container.
h) There driver then use an air gun to blow free any residue from the rotary valve
and clean the discharging accessories before placing them back into the SDU.
i) During the container truck out, the container must be inspected by the guard and
the driver must ensure all documents related to the discharge have been
compiled properly.

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 Pioneering the Future of Bulk
Logistics in Asia
Emergency response and
countermeasures

In the event of any incident involving contamination or injury, the driver must seek assistance by
calling out the emergency service required to the scene.

j) The driver will not leave the scene of the incident until the emergency service has
taken charge of the situation.
k) The driver must contact the Depot at the earliest possible moment to inform them
of the situation.

In the case of contamination, the emergency response process flow according to 4 stages:

FIRST STAGE
Emergency Report

SECOND STAGE
Site assessment and analysis Alert customer and
supplier of the situation at
hand

THIRD STAGE

Propose on site solution to Situation not suitable to

counter issue and resolve it resolve at site. Container must
there and then be withhold from discharging.

Permission given Arrange a meeting with

by customer and customer and supplier for a
supplier post mortem session and
propose best action taken.

FORTH STAGE
Execute
Execute

Feedback Report and Feedback Report and

improvements to prevent improvements to prevent
issues from happening again issues from happening again

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In the event of any incident, a NSER (Non Standard Event Report) will be generated by UBC and
sent to the customer/ supplier for review at the Second stage.
The NSER is a document containing the following details:

SAMPLE

Diagram shows the NSER form which will be prepared by UBC technical department

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For emergency response the following personal to be contacted for the correct channel:

ITEM DESCRIPTION CONTACT PERSON CONTACT NAME

Technical Issues related to: David Tan Mun +6016-3312926

Support a) Contamination of customer Choong- Technical
product Department
b) SDU breakdown
c) Silo retrieval
d) NSER report
Commercial Issues related to: Yuen Chee Meng – +6012-3902926
Support a) Billing Sale Department
b) Discrepancy in order
Administrative Issues related to: Ong Bee Cheng – +6016-2222926
Support a) Late delivery Administrative
b) Offset schedule delivery Department
UBC Regional Office Number: +603-33422926

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 Pioneering the Future of Bulk
Logistics in Asia
Storage and maintenance

The SDUs are stored in our depot during non operation hours. Each SDU is inspected every forth
week to ensure that there is no leakage in the pneumatic and hydraulic system:

Below are the inspections done on the SDU to prevent contamination of delivered product:

a) air filters inspection

- The air filters must be inspected frequently to prevent any clogging.

b) air piping fitting inspection

- The fittings must be tighten properly to prevent any leakage or debris getting into the air
line.

c) blower bolt nuts and oil containment inspection

- The gaskets and bolt nuts must be secure so that no oil will reach into the blowing
system.

d) hydraulic tank inspection

- The hydraulic tanks must be inspected to ensure no oil will leak onto the pneumatic line.

e) Control valves and check valves inspection

- These valves must be check to prevent air leakage.

The stainless steel accessories are stored in proper sheltered area and not exposed to rain
as it will cause smudging on the surface that will contribute to contamination.

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