{"id":3605,"date":"2026-10-09T08:59:13","date_gmt":"2026-10-09T00:59:13","guid":{"rendered":"http:\/\/www.hewilson.com\/blog\/?p=3605"},"modified":"2026-10-09T08:59:13","modified_gmt":"2026-10-09T00:59:13","slug":"how-to-measure-the-remaining-liquid-in-an-800l-ibc-tank-4cb2-1c2320","status":"publish","type":"post","link":"http:\/\/www.hewilson.com\/blog\/2026\/10\/09\/how-to-measure-the-remaining-liquid-in-an-800l-ibc-tank-4cb2-1c2320\/","title":{"rendered":"How to measure the remaining liquid in an 800L IBC Tank?"},"content":{"rendered":"

As an 800L IBC tank supplier, I talk to our customers all the time about a quiet, everyday frustration: \u201cI never know how much liquid is left in my tank.\u201d It sounds simple, but if you\u2019re running a food production line, chemicals lab, or construction site where materials like edible oil, solvents, or cleaning agents go into these bulk containers, guessing wrong can mean unexpected downtime, wasted product, or even safety issues that put your team at risk. I\u2019ve worked with hundreds of clients to solve this exact problem, and over the years I\u2019ve learned that the right way to measure remaining liquid isn\u2019t one-size-fits-all\u2014it depends on what you\u2019re storing, why you need the data, and how your operations work. Let\u2019s walk through the practical, science-backed methods we share with every one of our clients, no jargon, no guesswork. 800L IBC Tank<\/a><\/p>\n

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First, let\u2019s get one thing straight: 800L IBC tanks are not uniform, and \u201cempty\u201d doesn\u2019t mean the same thing for every substance. Our standard 800L IBC tanks have dimensions that are consistent, but the shape of the liquid inside shifts based on viscosity\u2014how thick it is. For example, a thin liquid like water or ethanol settles perfectly flat, so measuring the surface is straightforward. A thick liquid like honey or industrial grease clings to the walls and bottom, leaving a small, immovable pool even when it looks like the tank is empty. That\u2019s why the first step before any measurement is to define two things: what you\u2019re storing, and what you plan to do with that data. Are you just checking if you need to reorder in a week, or do you need exact measurements for process accuracy? That choice will narrow down the best method by half.<\/p>\n

Let\u2019s start with the method that\u2019s been around for decades, and still works for most routine, low-stakes checks: dip-stick measurement. This is the most low-tech, low-cost option, and it\u2019s the one we recommend for customers who store simple, non-corrosive liquids like water or basic cleaning solutions. Here\u2019s how to do it right, because most people get this wrong without realizing. First, never use a random stick or piece of scrap metal. Get a rigid, smooth stick\u2014wood, plastic, or stainless steel works\u2014and mark it clearly every 10cm, with a large, bold mark at the 80cm level (which aligns to the full 800L mark on our standard IBC). Next, open the top bung of the IBC slowly, to avoid splashing and creating a false liquid surface. Lower the dip-stick straight down until it touches the bottom of the tank, don\u2019t angle it or let it rest on the side walls. Hold it there for 10 full seconds, then pull it straight out, fast. For thin liquids, the mark will show a clear, wet line right at the surface\u2014wait for the stick to stop dripping before reading it. For thicker liquids, you\u2019ll see a wet band, and the rest of the stick will stay dry (or have a faint residue). That band is your true liquid level, not the tiny drips that run down the side.<\/p>\n

I\u2019ve seen customers skip the 10-second wait and get a reading that\u2019s off by 20L or more, because they pull the stick out too early before the liquid settles. I\u2019ve also seen people use a flexible tape measure, which bends against the tank walls and gives a reading that\u2019s lower than actual volume, because the tape conforms to the curve of the IBC\u2019s base. For most small businesses, this method is all they need\u2014no extra equipment, easy to train staff on, and accurate enough for routine checks. The only downside is it\u2019s not great for high-traffic operations where you need real-time data, or for storing corrosive liquids that could damage a dip-stick over time.<\/p>\n

If you need more accuracy, or you work with liquids that are corrosive, flammable, or too thick for dip-sticks, the next step is a level sensor. As a supplier, we work with several types of sensors that fit standard 800L IBC tanks, and we help customers pick the right one for their specific application, not just the most expensive. The three most common sensor types are ultrasonic, pressure, and float. Let\u2019s break them down.<\/p>\n

Ultrasonic sensors are the most popular for general use because they\u2019re non-contact\u2014they mount on the top of the IBC, send sound waves down to the liquid surface, and calculate the distance based on how long it takes the wave to bounce back. That means no part of the sensor touches the liquid, so they work for corrosive or sensitive substances like food-grade syrup or pharmaceuticals, where contamination is a risk. The accuracy is usually within 1-2%, which translates to less than 10L error in an 800L tank\u2014way better than dip-sticks. The catch with ultrasonic sensors is that they don\u2019t work well for foamy liquids (like some detergents) or thick, viscous liquids that create uneven surfaces, because the sound wave bounces off the foam or the clumps instead of the actual liquid surface. We always warn customers storing these substances to skip ultrasonic and go for a pressure sensor instead.<\/p>\n

Pressure sensors work on a simple physics rule: the pressure at the bottom of a liquid is directly proportional to its depth. So a pressure sensor mounted at the base of the IBC measures the force of the liquid above it, and converts that to volume. This method is incredibly accurate, even for foamy or viscous liquids, because it measures the total mass of liquid, not the surface. For example, if you\u2019re storing a thick industrial lubricant that leaves a residue on the sides, the pressure sensor still counts every drop, so you\u2019ll get an exact reading down to the litre. The downside is that the sensor is in contact with the liquid, so you have to choose a model made from material that\u2019s compatible with your substance. For food-grade products, we recommend stainless steel sensors that meet FDA standards; for harsh chemicals, we use sensors coated in polypropylene or PTFE that resist corrosion. We also calibrate every sensor before it ships, but we recommend annual recalibration to make sure the reading stays accurate, especially if the liquid\u2019s density changes over time (for example, if a chemical settles at the bottom of the tank).<\/p>\n

Float sensors are the cheapest option for semi-automated measurements, and they work for a wide range of non-corrosive, low-viscosity liquids. They\u2019re basically a plastic or stainless steel float that sits on top of the liquid, connected to a small rod that runs up to the top of the IBC. As the liquid level rises or falls, the float moves, and the rod sends a signal to a gauge that shows the volume. Float sensors are simple to install, and they don\u2019t require any wiring or power if you get a mechanical model\u2014great for remote sites where power is limited. The downside is that they can get stuck if the liquid is very viscous, or if there\u2019s debris in the tank. I once worked with a construction company that used a float sensor for concrete cleaner, and the small particles in the liquid got caught around the float, leading to a reading that was 50L off for three weeks before someone noticed. For that reason, we always suggest float sensors only for clean, thin liquids that don\u2019t have sediment.<\/p>\n

Now, let\u2019s talk about two common scenarios that I see again and again, and the best method for each. First, if you\u2019re a small caf\u00e9 or food manufacturer storing edible oil for your fryers. You need to check the level once or twice a week, and accuracy to within 20L is enough. A dip-stick works here, but if you want to cut down on labour, a basic float sensor is the perfect fit\u2014it\u2019s cheap, easy to install, and you can check the level without opening the top of the tank. Second, if you\u2019re a chemical lab storing corrosive solvents, where even a tiny measurement error could lead to ordering too much and wasting expensive material. A pressure sensor is the right choice\u2014no contact means no contamination risk, and it\u2019s accurate to within 1%, so you\u2019ll never overorder or run out unexpectedly.<\/p>\n

One thing I always emphasize with customers is that measurement accuracy isn\u2019t just about the tool\u2014it\u2019s about the tank itself. Our 800L IBC tanks are calibrated at the factory, so the volume markings on the side are exact, but after repeated use, the bottom of the tank can get dented, or residual liquid can build up in the corners, which throws off readings. That\u2019s why we recommend a full tank cleaning and inspection every 6 months, especially if you store different substances in the same IBC. If you\u2019ve had an IBC that\u2019s been used for 2 or 3 years, a quick dip-stick test against your sensor reading can tell you if it\u2019s time to recalibrate or replace the tank\u2019s measurement marks.<\/p>\n

I also get a lot of questions about visual checks. \u201cCan I just look through the side of the IBC to see how much is left?\u201d It makes sense, right? Many IBCs have a translucent plastic side, so you can see the liquid level. But here\u2019s the problem: most translucent IBCs only show the liquid level accurately when it\u2019s between 20% and 80% full. Below that, the liquid clings to the bottom walls, and above that, the liquid fills the top corners, so the line looks higher than it actually is. I tested this myself last year with a client\u2014we had a translucent 800L IBC full of water, and the visual line at the top looked like it was 850L, when it was actually 800L. That\u2019s a 50L mistake from just looking. And for opaque IBCs, which are common for storing light-sensitive substances, visual checks are impossible. So save yourself the guesswork\u2014skip the eyeball method for anything beyond a rough estimate.<\/p>\n

At the end of the day, measuring remaining liquid in an 800L IBC tank is about avoiding hassle, saving money, and keeping your operations running smoothly. Over my years as an IBC supplier, I\u2019ve seen clients save thousands of dollars just by switching from guesswork to a consistent measurement method\u2014no more rushing to order material at 5pm on a Friday, no more wasting half a tank of product because of a bad reading, no more safety risks from handling flammable liquids when you think you have more than you do.<\/p>\n

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If you\u2019re tired of guessing how much liquid is left in your IBC, and you want to talk about which measurement method fits your specific needs, we\u2019re here to help. We can walk you through all the options, recommend compatible tools, and even calibrate your IBC tanks to make sure your readings are accurate. All you need to do is reach out, and we\u2019ll work with you to find a solution that fits your budget and your operations.<\/p>\n

Plastic Parts<\/a> References<\/p>\n

    \n
  1. American Society of Mechanical Engineers (ASME). Measurement of Liquid Level in Portable Bulk Containers. ASME PTC 19.1-2013, 2013.<\/li>\n
  2. National Sanitation Foundation (NSF). Standards for Equipment and Utensils in Food Service. NSF\/ANSI 2, 2021.<\/li>\n
  3. International Organization for Standardization (ISO). Series 1 Freight Containers – Specifications and Testing. ISO 1496-1:2019, 2019.<\/li>\n
  4. Occupational Safety and Health Administration (OSHA). Safety Guidelines for Bulk Chemical Storage Containers. OSHA 3374-06R, 2020.<\/li>\n<\/ol>\n
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    Jiangsu Xinhuasheng Packaging New Materials Co., Ltd.<\/a>
    Jiangsu Xinhuasheng Packaging New Materials Co., Ltd. is one of the most professional 800l ibc tank manufacturers and suppliers in China, featured by quality products and low price. Please rest assured to wholesale durable 800l ibc tank in stock here and get quotation from our factory. Customized orders are welcome.
    Address: No. 5 Tieta Road, Industrial Park, Guyang Town, Dantu District, Zhenjiang City, Jiangsu Province, China.
    E-mail: manager@jsxhsgs.com
    WebSite:     https:\/\/www.xhsibc.com\/<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"

    As an 800L IBC tank supplier, I talk to our customers all the time about a … How to measure the remaining liquid in an 800L IBC Tank?<\/span>Read more<\/a><\/p>\n","protected":false},"author":99,"featured_media":3605,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[3568],"class_list":["post-3605","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-industry","tag-800l-ibc-tank-45d5-1c673a"],"_links":{"self":[{"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/posts\/3605","targetHints":{"allow":["GET"]}}],"collection":[{"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/users\/99"}],"replies":[{"embeddable":true,"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/comments?post=3605"}],"version-history":[{"count":0,"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/posts\/3605\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/posts\/3605"}],"wp:attachment":[{"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/media?parent=3605"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/categories?post=3605"},{"taxonomy":"post_tag","embeddable":true,"href":"http:\/\/www.hewilson.com\/blog\/wp-json\/wp\/v2\/tags?post=3605"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}