Bulk Salt Storage and Transportation Best Practices

Salt is one of the most widely used commodities in various industries. Whether you are in the winter road maintenance, food industry, or manufacturing operations, the storage and transportation of salt are crucial. Salt can be a simple substance, but when it comes to bulk quantities, it can be challenging to handle. There are chances of contamination, clumping and environmental concerns if the bulk salt is not handled properly. In this article, we will discuss best practices for bulk salt storage and transportation.

Why Proper Salt Handling Matters?

Salt naturally attracts moisture from the air. If left in humid conditions, a lot can become mushy or clumpy, and the situation can worsen because the clumps need to be reprocessed to reuse them. In winter, the salt needs to be loose and easily flowable to use it efficiently. Therefore, following best practices for the transportation and storage of bulk salt is important.

Handling bulk salt properly can save you money. Efficient storage and transportation can reduce waste, address environmental concerns, and ensure safety for both workers and drivers. Storing salt is not just a commodity, but also a valuable asset.

Common Types of Salt Used in Bulk

Not all the bulk salts are the same. The type of salt you need depends on the industry in which you operate. You might be using the following salts:

• Rock Salt (Halite): It is commonly used as a deicing agent. It is affordable and available in a crystal form.
• Solar Salt: It is the purest form of salt, compared to rock salt, and is primarily used in the production of water softener salts or food-grade salt.
• Evaporated Salt: Obtained from the evaporation of salt brine. Mostly preferred by the food processing and pharma industries.
• Treated Salt: Salt which is combined with anti-caking agents or other additives to improve its efficiency in icy conditions.

All the above salts have their own storage and transportation requirements. For example, food-grade salt must be stored in clean conditions to prevent contamination. Whereas, road salt can be stored outside in proper conditions.

Choosing the Right Salt Storage Facility

Ideal Locations for Bulk Salt Storage

Location is not just a space for storage; it should be easily accessible by every logistics chain of the salt distribution company. A proper bulk salt storage should be:

• Close to Delivery Points: Whether it’s a food processing unit or a municipal road depot, you can avoid higher delivery costs and delays by being located near the point of use.
• Good Drainage: The storage site must be elevated to prevent water from seeping into the salt pile.
• Year-round Accessibility: The storage facility should be situated in a manner that prevents snow or mud from making access challenging.

Also, consider the local weather conditions. If the facility is located in a humid region, it should be stored in a closed space to maintain its natural form. However, if the region is dry, open storage can also be effective with proper cover.

Indoor vs. Outdoor Storage Options

Bulk salt storage options are of two types: indoor structures, which can be domes or warehouses, and outdoor piles, which can be covered with tarps or custom covers. Each storage option has its pros and cons.

Indoor Storage:

• Pros: Offers great protection from the external elements. Fewer chances of contamination and leaching.
• Cons: The construction and its maintenance costs can be high. It also comes with ventilation challenges.

Outdoor Storage:

• Pros: Low to no-cost storage, which can be quickly and easily set up.
• Cons: Requires careful protection from weather challenges, as there is a risk of salt runoff, and adherence to strict rules is necessary to maintain quality.

Temporary shelters, also known as hoop barns, can be a hybrid approach that offers the benefits of both indoor and outdoor storage options.

Environmental Considerations

A proper salt storage facility is required to prevent serious environmental concerns. Salt runoff can cause elevated salinity levels, damage to nearby ecosystems, including aquatic life, trees, and grass, and may lead to contamination of drinking water supplies. The following points need to be followed to stay compliant and responsible:

• Construct containment systems like slit fences and berms
• Monitor for salt runoff after rainfall
• Use liners under the salt pile to prevent water or moisture from seeping into the salt

Also, be sure to store salt away from areas that are prone to moisture, such as wetlands. Following EPA rules and regulations is far more than just ticking the box. It’s been about environmental protection for a long time.

Design and Construction of Salt Storage Buildings

Recommended Structural Materials

Salt is a highly corrosive material. Therefore, select those that can withstand the corrosive nature of the salt. Below are the materials that can handle the salt’s nature:

• Concrete: Works great for floors and base walls. If it is sealed properly, it can resist corrosion and last longer.
• Galvanized or Stainless Steel: Regular steel or iron can rust and slowly be damaged. So, use galvanized steel for beams and fasteners.
• PVC or Polyethylene Covers: These are temporary protection that are laid below or upon the salt piles to prevent water from entering the salt pile.

Ventilation and Moisture Control

Moisture is a silent challenge you need to face if you are dealing with a bulk salt storage facility. If there is no proper air flow, the salt can become clumpy and unusable. Prevent this by:

• Installing proper ventilation systems, like fans and louvres, for proper air flow
• If the building is tightly sealed, use dehumidifiers to control moisture inside the facility.
• Always check for any leaks from the roof or walls.
• Using floor drains and moisture-resistant coatings can increase the lifespan of the storage facility.

Accessibility and Loading Efficiency

Maintaining speed and safety is important in salt operations. Your facility should have access to vehicles like:

• Trucks or rail cars
• Front-end loaders or conveyors
• Maintenance crews

Ensure your salt storage facility is easily accessible to vehicles without any delays. Build wider entrances with reinforced ramps, slip-resistant floors, and better overhead clearance for large vehicles. A well-planned loading and unloading can save you time and fuel.

Best Practices for Bulk Salt Storage

Preventing Contamination and Clumping

If salt is stored in bulk quantities, there is a high chance of moisture and other contaminants being drawn into the salt pile, which can cause clumping and eventually lead to a loss of effectiveness. Prevent this by following the steps mentioned below:

• Store the salt on a properly sealed surface or one with a waterproof lining. Never store on gravel or bare ground.
• Cover the salt pile, even indoors, during the humid season to maintain its quality.
• Do not mix old salt with new salt, as contamination can occur, rendering the salt unusable.
• Limit the humidity in the air inside the storage facility or install humidity sensors to receive alerts when the humidity level exceeds the set limit.

FIFO Method

The first-in, first-out method (FIFO) is a valuable inventory management technique employed by many industries. In this method, using the older salt becomes the priority, which prevents spoilage and wastage. It ensures that the salt remains in good condition. Here’s how to do it in the right and effective way:

• Label the date on every delivery on the day of arrival
• Place the new stock behind or beside the older stock
• Use signage to indicate the usage order and prevent the accumulation of old stock

The FIFO approach helps the salt maintain its good condition and prevents the discarding of unusable salt clumps.

Maintenance and Monitoring Protocols

You need a proper maintenance plan while storing salt. It includes:

• Daily visual inspections for moisture intrusion, leaks, or damage.
• Weekly cleaning of equipment and floors to prevent corrosion.
• Monthly audits of inventory levels, pile stability, and structural health.

Most of us assume that monitoring is only for salt. Still, you also need to monitor the storage facility and handling equipment. Address minor repairs upfront to prevent costly repairs.

Transportation of Bulk Salt

Transportation Methods: Truck, Rail, and Ship

Transportation of salt can be accomplished in various ways, each with its advantages and disadvantages. Make your choice based on the cost, distance, quantity, and requirements. The most common methods are:

• Trucks: These vehicles are used to deliver road salt in local areas. Delivery points with less distance can be covered quickly with the help of trucks. They are flexible, but weight regulations and fuel costs may limit them.
• Rail Cars: Rail transport is well-suited for transporting large quantities of salt over long distances. It utilizes hopper cars, which facilitate easy unloading with the aid of gravity. By utilizing rail transport, we can reduce road traffic; however, your storage facility must have access to a rail line.
• Ships and Barges: Transporting salt through the sea is ideal for bringing the salt from mines or evaporation plants to different countries. Ships and barges are ideal for handling large quantities, but the port should have proper facilities. These transportation methods usually take longer, and delays can happen depending on the weather conditions.

Each way of transporting salt has its challenges and requires different equipment and setup. Depending on the situation, you can combine these methods to streamline the process and save money simultaneously.

Loading and Unloading Guidelines

Loading and unloading can seem simple, but they are quite challenging. You can avoid loss and contamination by handling the bulk salt with utmost precision and care. Some guidelines are:

• Use Clean and Dry Equipment: Ensure that the hoppers, loaders, or containers are dry and free from moisture, as they can cause clumping of the salt.
• Use Conveyors: These systems efficiently move large quantities of salt, minimizing excessive spillage and waste.
• Avoid Overloading Vehicles: Overloading can result in spills, fines, and damage to loading surfaces and roads.

Unloading should be done on a solid and sloped surface for easier cleanup. Smartly park the vehicles to avoid turning time and fuel costs. If you have chosen rail transport, consider investing in a gravity-assisted unloading system, which can help you avoid handling costs. For ships or barges, unloading will be carried out by large cranes and vacuum systems, which can reduce labour costs and environmental exposure.

Preventing Loss During Transit

Loss of minimal quantities of salt is common during transportation. However, when it is used in larger quantities, it is not only a cost factor but also an environmental concern, as it can seep into the soil and surrounding water systems. You can avoid that by:

• Covering Tarps on Open Loads: This is a simple yet effective method of covering the salt pile to reduce loss from external elements, such as wind or rain.
• Use Sealed Containers: Fine salts have smaller crystals, which can be easily swept away. Therefore, use sealed containers to prevent this issue, especially for solar or evaporated salts.
• Secure Doors, Hatches, and Lids: Loose fittings can cause leakage during transportation, especially on rough terrain.

Transport vehicles need to have spill kits. In the event of any salt spillage, the driver or workers must handle the spills, which include containment, cleanup, and reporting to the relevant authorities.

Packaging and Containerization for Transport

Bulk Bags, Silo Trucks, and Hopper Cars

The packaging method of salt can directly affect various factors, such as transportation. Safety and cost. Some of the most commonly used ways to pack salt include:

• FIBC Bags or Bulk Bags: Flexible Intermediate Bulk Containers (FIBC bags) are most commonly used for moderate amounts of salt. It keeps the salt protected from external elements, and it can be easily stacked and transported.
• Silo Trucks: These are mostly preferred for fine salt due to their air-tight and moisture-resistant features. Silo trucks are chosen by industries that require contamination-free delivery, such as food production and water treatment.
• Hopper Rail Cars: These are a rail-assisted mode of transport system used for large volume deliveries. They feature a gravity unloading system, making the process easy and quick, and can be sealed to prevent contamination of the salt.

Your volume of usage and the infrastructure determine which method you should choose. For example, FIBCs are ideal for small batches but can be challenging for companies with continuous operations.

Technology in Salt Storage and Transport

Automation and Smart Inventory Systems

Including technology in your salt logistics can transform the business from a reactive task into a proactive system. Leverage automation tools like:

• Smart weigh scales to automatically detect and track incoming and outgoing salt loads.
• Inventory sensors to measure huge quantities of salt piles. They are installed in the salt piles and provide you with real-time data, notifying you whenever the levels are low.
• Automated conveyor systems to reduce labour and human errors. These also expedite the loading and unloading process, resulting in reduced waste.

These tools integrate with each other, providing you with insights regarding salt levels and notifying you about reorder times, so you can plan for restocking salt, especially during high-demand seasons.

GPS and Fleet Tracking

Most salt companies deal with longer-distance deliveries. Therefore, having a GPS and fleet tracking system is crucial for tracking routes and providing proof in the event of any delays. They offer:

• Real-time location monitoring
• Route optimization
• Driver safety alerts
• Delivery time estimates

Data Analytics for Efficiency

Salt can be an old commodity, but the way you handle it can be modern. Using data analytics can help you to:

• Forecast demand based on weather predictions and historical usage.
• Ensure proper storage by following the FIFO method..
• Reduce waste and spoilage by identifying and fixing the problems in your organization.

Conclusion

Bulk salt handling may seem simple, but without the right storage and transportation, it can lead to serious complications. Whether you are using it for water treatment, food processing or for roads, logistics and storage play a key role in maintaining the effectiveness of the salt. At Canada Salt Group Ltd, we offer more than just high-quality bulk road salt. We offer full-service support, from secure storage options to reliable bulk transportation. Our team follows the best practices to maintain the salt dry, clean and ready to use. Contact us today to receive a complimentary quote.