Projects completed

Beyond Drums and IBCs: How to Optimize Space and Manage Leaks with Containment Sumps

When we talk about containment tanks in industry, the mind immediately turns to the static storage of the great classics of chemical logistics: 200-liter drums and 1000-liter IBC tanks. But the operational reality of a workshop or a production department presents much more dynamic, daily, and complex challenges. At Mayermoover, in our role as operational partners for purchasing departments and safety, we know well that regulatory compliance and space efficiency do not follow predefined layouts. Recently, we supported a client in developing an integrated project that demonstrates how steel containment tanks can be transformed into real tools for optimizing layout and preventative maintenance. Here's how we solved two critical problems within the same plant. 1. The containment tank as an operational base for machinery with oil micro-leaks The first problem encountered by the client concerned a hydraulic control unit. As happens with many operational machines subjected to high pressures and continuous cycles, the control unit showed physiological micro-leaks of lubricating oil. The consequences of these constant drips on the department floor are well known to anyone managing production: Concrete risks of slipping and injuries for operators (in violation of Legislative Decree 81/08). Premature deterioration of the company flooring and horizontal signage. Downtime and continuous costs related to cleaning with absorbent materials (sawdust, cloths, or powders). The applied solution: We reversed the classic concept of storage. Instead of placing the tank in a corner of the warehouse, we placed the machinery itself directly on top of a carbon steel containment tank with a high-capacity galvanized grating. In this way, the tank no longer acts only as a "safety deposit," but becomes the operational base of the control unit. Any residual leaks or oil drips are immediately intercepted by the grating and conveyed into the collection tank below, keeping the work area perfectly dry, clean, and compliant with regulations. The robust steel structure also ensures maximum stability of the machinery even during operational vibrations. 2. The jerry can storage island: millimeter-precise under-shelf optimization The second challenge of the project concerned the logistical management of daily consumables. The client needed to organize a secure storage area for numerous 25-liter plastic jerry cans containing technical fluids. However, the available space on the department floor was extremely limited. By analyzing the department layout with the purchasing department, we identified an opportunity: a vertical "dead space" located directly under the first beam of an existing pallet rack. The applied solution: To utilize this niche without hindering normal pallet loading and unloading operations, we installed a low-profile storage tank structured as a custom island. The tank is equipped with forklift fork supports (to facilitate any emptying or handling operations) and was dimensioned to the millimeter in width and depth to integrate under the racking uprights. The result? The blue jerry cans are now organized, perfectly accessible to operators for routine top-ups, and placed on a compliant collection surface. This solution allowed for zero ground footprint of a new storage area, recovering volumetric space that would otherwise have remained unused. Industrial "Tailor-Made" as a Driver of Efficiency This field project highlights the importance of not stopping at standard catalog solutions. Whether it's managing leaks from a hydraulic motor or designing custom non-standard containment tanks — a field in which Mayermoover is a unique reference point in Italy, also for stainless steel constructions — the key is the engineering approach applied to real workshop problems. Thanks to intelligent, digital, and flexible solutions, environmental safety ceases to be a mere compliance cost and transforms into a competitive factor for optimizing time, space, and logistical resources. Do you want to optimize your plant's spaces or bring your operating machinery up to standard? Discover our complete range of tanks and storage depots for industry or contact our technical department to develop a custom project or receive a quick quote.