What is a Two Tier Barn Door?
What is a Two Tier Barn Door?
The CustomBulk team at RPP Containers pushes the envelope and defines what is possible in the industry. Today’s market allows for inspiration to come from seemingly anywhere, where concepts become a reality. Our process was not an overnight epiphany but a dedication to a craft and a collaboration between experts with years of experience in seeing the problem and creating the solution.
When a client reaches out and says they have a great product, but the boxes they use currently are less than desirable, that’s where we make magic happen. Our goal is to always begin a project with our client saying: “wow, I am really glad I called those guys”.
Concept and Design
One such design that went through many iterations over the span of a year is the two-tier barndoor container. Tasked with holding small bags of food-grade powder, this container has streamlined the process of transporting from its initial vendor to final production due to targeted unique characteristics.
As a quick disclaimer: all specific client information has been removed from this entry, and some details have been removed to further protect our client’s privacy. This design from start to finish is a production of RPP Containers and its partners.
After some initial metrics were gathered, the prototype design was a basic cut/weld of our DGR454850-2 bulk container. The result was a product capable of holding significant weight and withstanding extreme side wall pressure. Testing was done by filling, from floor to top, the container with water and performing anticipated tasks the customer described from their process. Due to the overall height and non-collapsible nature, this container was not expected to be stacked in transit or in storage.
Updating the Design
This prototype would likely have potential as a finished product in many scenarios, but for this project the result would need to be an FDA solution, so this would ultimately just be a tester for the client. Speaking candidly, it was an absolute tank of a container and performed admirably for the allocated budget. Its trial at the client’s site, feedback was that we would need to slim down, switch to all stainless-steel hardware, and white was the desired color.
An updated design was drafted where the permanent top was incorporated to add additional stability. Here we replace the cut/weld material with all virgin HDPE sheeting and all the frame with stainless-steel. All smoothed down again to prevent snags and sharp edges from impacting production.
This design uses less plastic material overall but more metal. Budget was increased to compensate for these significant changes. As before, initial testing was done at RPP to ensure safety and performance and then the unit was sent to our client’s site for final approval. Feedback was thoroughly positive, and this was the model for the production units. Final dimensions measuring 40 x 45 x 81” with rigidity for a dynamic load of over 2,000 lbs.
Today, RPP Containers continues to produce projects like this for customers all over North America and beyond. We are a hub of industry knowledge with the experience to design uncommon solutions for our respected clients. Please don’t hesitate to reach out if you have any questions about this or any of our products. Thank you.
