The 55 Gallon Drum has been one of the most recognized and widely used industrial containers for decades. Known for its durability and standardized size, the fifty five gallon drum is used across industries to store, transport, and dispose of liquids, solids, and hazardous materials. Whether in the form of a 55 Gallon Steel Drum or a Plastic 55 Gallon Drum, these gallon barrels have shaped global logistics for generations.
Yet the limitations of traditional 55 Gallon Barrel designs are becoming harder to ignore. They are heavy, rigid, space-consuming, and increasingly costly to store and transport. Even though companies continue to buy 55 gallon drums for their operations, many are actively seeking more efficient and sustainable alternatives. This guide explores the shortcomings of traditional gallon barrels, why Gorilla Drum is the superior choice, and how businesses can improve cost efficiency, safety, and sustainability by adopting modern alternatives.
Why Gorilla Drum Outperforms Standard 55 Gallon Barrels
For decades, the 55 Gallon Barrel Metal container has been considered the industry standard. However, its design is rooted in older logistics models that no longer match the efficiency demands of modern businesses. As supply chains become more complex and sustainability targets become more urgent, the shortcomings of traditional steel and plastic drums are becoming more evident. Companies are reevaluating whether sticking with a rigid, heavy, and costly container truly makes sense in today’s world.
The limitations of traditional drums
The 55 Gallon Steel Drum was originally valued for its durability, stackability, and standardized size, which allowed it to fit neatly into shipping systems across industries. However, what was once seen as an asset is now more of a liability.
A steel drum weighs more than 40 pounds when empty, and when filled, it can exceed 400 pounds depending on the contents. Moving such a container is not only labor-intensive but also dangerous without the use of forklifts, drum clamps, or heavy-duty dollies. Each movement requires time, equipment, and trained personnel, adding layers of cost and risk.
Plastic 55 Gallon Drums, introduced later as an alternative, addressed some issues such as rust and corrosion. They are lighter than their steel counterparts, and in certain industries—such as food and beverage or pharmaceuticals—they provide more hygienic storage. Yet, despite these advantages, plastic drums remain bulky and rigid. They take up just as much space empty as they do full, forcing businesses to allocate vast warehouse areas for containers that aren’t even in use.
In both cases, the lack of flexibility results in inefficiencies. Rigid gallon barrels require companies to dedicate expensive real estate to storage and invest in fleets of forklifts or handling tools. Even then, the risk of accidents remains high, as heavy containers are a common cause of workplace injuries.
Structural and durability concerns
Although steel drums are strong, they are not immune to damage. Dents, punctures, and corrosion can render a 55 Gallon Barrel unsafe to use. Lined steel drums attempt to address corrosion concerns, but linings eventually peel or crack, especially under chemical stress or after multiple uses. Once compromised, they must be discarded or recycled, which adds disposal costs.
Plastic drums, on the other hand, may not rust, but they are vulnerable to UV degradation when stored outdoors. Over time, they can become brittle and prone to cracking, particularly in high-temperature or high-stress environments. This fragility shortens their service life, leading to more frequent replacements.
For businesses that frequently buy 55 gallon drums, these recurring problems create a cycle of inefficiency: purchase, use, replacement, and disposal.
Cost implications
The financial impact of these inefficiencies is significant. Heavier containers translate to higher shipping costs, as carriers charge based on both weight and space. Warehouses filled with unused, empty drums cut into valuable square footage that could be allocated to revenue-generating inventory. In addition, the need for specialized equipment and labor to handle drums adds another layer of expense.
When viewed across large-scale operations, the total cost of ownership for steel and plastic drums is much higher than their sticker price. Businesses end up paying not just for the drum itself but also for the ripple effect it creates across storage, logistics, and safety management.
The Gorilla Drum solution
Recognizing these long-standing challenges, Gorilla Drum was developed as a smarter, more sustainable alternative to traditional gallon barrels.
Lightweight yet full capacity
Constructed from recyclable polypropylene, Gorilla Drum weighs only 7.5 pounds when unfilled, a fraction of the weight of steel or even plastic drums. Despite its light weight, it still maintains the standard fifty five gallon drum capacity, ensuring no compromise in volume. This balance of strength and efficiency makes it easy for workers to handle without requiring constant reliance on forklifts or heavy machinery.
Collapsible for space efficiency
The collapsible design is where Gorilla Drum sets itself apart. Unlike rigid steel or plastic gallon barrels, Gorilla Drum can be folded flat when not in use. This dramatically reduces the amount of storage space required in warehouses and during transport.
To put it in perspective: a single truckload can carry about 208 traditional steel drums. The same truck can carry over 4,000 Gorilla Drums in their collapsed state. That’s nearly 20 times more efficient, resulting in lower freight costs, fewer trips, and reduced carbon emissions. For businesses, this means not only cost savings but also progress toward sustainability goals.
Built for safer handling
Gorilla Drum isn’t just about capacity and space—it’s about safety. The container is equipped with lift loops, dolly straps, reinforced zippers, and belly bands that simplify movement and reduce injury risks. Traditional 55 Gallon Barrel Metal containers demand strength and equipment to maneuver, but Gorilla Drum empowers workers to move containers more safely and efficiently.
This focus on ergonomics and safety translates into fewer workplace accidents, lower insurance premiums, and a safer environment for employees.
Performance and compliance
Businesses that buy 55 gallon drums must ensure compliance with stringent regulations, especially when transporting hazardous materials. Gorilla Drum has been engineered with this requirement in mind.
Despite being lightweight, it maintains a 6:1 safety factor and can safely hold up to 452 pounds of material. It has also been stack tested to 1,000 pounds, proving its resilience under pressure. Furthermore, it is certified under UN/DOT standards for transporting both hazardous and non-hazardous goods, offering the same compliance as steel or plastic drums without their drawbacks.
This ensures businesses do not need to choose between compliance and efficiency—they can have both in one innovative package.
Long-term benefits
By switching to Gorilla Drum, businesses can reduce operating costs, improve workplace safety, and reclaim warehouse space. The container’s collapsibility and light weight cut transportation expenses, while its durability minimizes replacement cycles. As industries continue to emphasize sustainability, Gorilla Drum’s recyclable construction also helps businesses reduce their environmental footprint.
In short, Gorilla Drum represents the next evolution of the 55 Gallon Drum Container. It solves the problems that steel and plastic drums have carried for decades while offering modern businesses the efficiency, safety, and compliance they need to thrive.
How To Store And Transport Materials Without Heavy Drums
One of the biggest challenges with a 55 Gallon Barrel is its heavy and rigid design. Storage and transportation inefficiencies quickly add up in terms of cost, space, and safety. Gorilla Drum provides a modern solution to these long-standing challenges, offering a lightweight, collapsible, and durable alternative that directly addresses the pain points of traditional gallon barrels.
Storing materials efficiently
Traditional steel and plastic drums take up the same amount of space whether they are full or empty. For companies that maintain large inventories of containers, this rigidity creates a significant storage problem. Warehouses are often stacked with hundreds or even thousands of empty drums, each one occupying floor space that could otherwise be used for inventory, equipment, or operational expansion. Over time, this results in wasted square footage, higher rent or property costs, and the need to build or lease additional storage facilities.
Even companies that attempt to stack steel drums face challenges. A 55 Gallon Steel Drum is extremely heavy, and while stackable, improper stacking can lead to instability and accidents. Plastic 55 Gallon Drums are somewhat lighter but still bulky, making them difficult to organize efficiently.
Gorilla Drum changes this equation by collapsing flat when not in use. A stack of unused Gorilla Drums occupies a fraction of the space of traditional gallon barrels. In fact, one pallet can hold up to 80 Gorilla Drums, compared to only four standard steel drums. This exponential increase in storage density allows businesses to maximize warehouse space, reduce clutter, and streamline operations. Workers can also move collapsed drums by hand, further eliminating the need for forklifts or specialized lifting equipment just to rearrange containers.
The collapsible design doesn’t just save space—it also simplifies inventory management. Instead of trying to account for stacks of rigid drums scattered across a facility, Gorilla Drums can be neatly stored in compact areas, ready to be deployed when needed.
Transporting materials safely
Transportation is another area where traditional drums reveal major shortcomings. A 55 Gallon Drum Container made of steel or plastic is rigid and heavy. Transporting them, especially when filled, requires secure strapping, palletization, and forklift handling. Even when empty, they take up a full drum’s worth of space, meaning freight companies charge for volume that isn’t being effectively utilized.
For example, a standard truckload can only fit about 208 steel drums. By contrast, when shipped collapsed, Gorilla Drums allow more than 4,000 units to fit on a truck. This represents a nearly 20-fold increase in efficiency. Fewer trucks mean lower freight costs, reduced fuel consumption, and smaller carbon footprints—all of which are critical for modern supply chains trying to remain competitive and sustainable.
Gorilla Drum also enhances safety during transport. Heavy steel drums can shift in transit if not perfectly secured, creating risks of spills, leaks, or cargo damage. Even minor impacts can dent or compromise a steel drum, while plastic drums may crack under stress. Gorilla Drum’s lightweight, flexible frame is designed to absorb movement without failure, and its reinforced double-zipper lid with a belly band provides a secure seal that reduces the risk of leaks.
This makes Gorilla Drum ideal not only for standard goods but also for industries transporting hazardous or sensitive materials that must comply with strict DOT and UN safety requirements. Businesses gain both peace of mind and regulatory compliance without sacrificing efficiency.
Safety improvements
Workplace safety is a pressing concern in any facility where heavy containers are in use. Traditional gallon barrels introduce a range of risks, from musculoskeletal injuries caused by lifting and rolling to accidents involving forklifts or dropped drums. Even a single incident involving a 55 Gallon Barrel Metal container can result in costly downtime, workers’ compensation claims, and regulatory investigations.
Gorilla Drum significantly reduces these risks through its lightweight design. At only 7.5 pounds unfilled, it can be handled by workers without straining or requiring powered equipment. Built-in lift loops and dolly straps give workers multiple secure points for safe lifting and maneuvering, while the collapsible nature of the drum minimizes the amount of clutter in storage areas. With fewer obstacles on the warehouse floor, the likelihood of trips, collisions, or falling stacks is reduced.
Another safety benefit comes from the material itself. Because Gorilla Drum is made from recyclable polypropylene, it avoids the corrosion and sharp edges often associated with aging steel drums. Workers no longer need to worry about cuts, rust exposure, or weakened containers failing under pressure. This not only protects employees but also reduces the potential for contamination of stored products.
Cost savings and operational efficiency
By addressing storage, transportation, and safety challenges, Gorilla Drum generates measurable cost savings across the entire logistics chain. Businesses that once allocated large budgets to rent additional warehouse space can now operate within smaller footprints. Shipping costs drop as truckloads are maximized, reducing both freight bills and emissions. Labor costs decrease as workers spend less time maneuvering heavy drums and fewer accidents lead to lost productivity.
Beyond cost, Gorilla Drum also improves overall operational efficiency. Because it’s easier to handle, companies can move products faster through their facilities, reducing bottlenecks and increasing throughput. This agility gives businesses a competitive edge in industries where timing and responsiveness are critical.
A smarter way forward
Traditional steel and plastic drums have served industries for decades, but their design reflects an era when logistics were less complex, storage space was cheaper, and safety standards were lower. Today’s businesses operate in an environment where every inch of space, every gallon of fuel, and every second of labor time matters. Gorilla Drum represents the evolution of the fifty five gallon drum—offering the same capacity without the limitations of weight, rigidity, or inefficiency.
By switching to Gorilla Drum, companies can streamline storage, simplify transportation, and create safer workplaces, all while reducing costs and improving sustainability. It’s not just a container—it’s a smarter logistics solution for a modern world.
The Cost And Safety Benefits Of Switching From Steel Drums
Switching from steel to modern alternatives like Gorilla Drum provides measurable cost and safety benefits for businesses across industries. While the fifty five gallon drum has long been considered the backbone of industrial storage and transport, its inefficiencies are increasingly difficult to justify. Gorilla Drum offers not just a replacement, but a comprehensive upgrade that transforms logistics, reduces costs, and protects workers.
Cost savings
The cost of using steel drums is more than just the purchase price. Businesses that buy 55 gallon drums must also account for the cumulative expenses tied to their use. These include freight, storage, specialized handling equipment, labor, and eventual disposal or recycling when the drums corrode, dent, or otherwise fail. Even the resale or scrap value of steel cannot offset the recurring costs of constant replacements.
Consider shipping costs: a single 55 Gallon Steel Drum weighs more than 40 pounds empty, and once filled, can exceed 400 pounds. This weight significantly increases freight charges. On top of that, their rigid design means they take up maximum space even when empty, forcing companies to pay for inefficient truckloads. A standard trailer can hold only about 208 traditional gallon barrels, compared to more than 4,000 Gorilla Drums when collapsed. This nearly twenty-fold difference translates directly into savings on fuel, labor, and shipping fees.
Storage costs also weigh heavily on businesses. Warehouses often dedicate entire sections to storing unused drums, consuming valuable square footage that could be used for higher-value inventory or production. Gorilla Drum’s collapsible design eliminates this waste by allowing companies to store more units in less space. Instead of occupying rows of shelves, hundreds of drums can be compactly stacked until needed.
Replacement cycles represent another hidden cost of traditional gallon barrels. Steel drums corrode, even when lined, and plastic drums degrade under UV exposure or stress. This constant turnover drains budgets and disrupts operations. Gorilla Drum’s recyclable polypropylene construction ensures a longer usable life while reducing waste. Fewer replacements mean lower long-term costs and less downtime waiting for new containers.
Safety advantages
In addition to costs, safety is a critical concern when evaluating storage and transport solutions. Handling heavy steel drums presents inherent risks for workers. Forklift accidents, back strains from manual handling, and spills from compromised containers are all common issues in facilities that use traditional 55 Gallon Drum Containers extensively.
Even lined steel drums, while offering temporary protection against corrosion, eventually degrade. Once the lining begins to peel or crack, the risk of leaks and contamination grows, creating hazards not only for employees but also for the surrounding environment. Plastic drums solve some of the corrosion problems but remain heavy when full and prone to structural weaknesses under stress, which can still lead to accidents.
Gorilla Drum is engineered with safety as a priority. At just 7.5 pounds unfilled, it eliminates the need for heavy machinery for every move. Workers can handle and maneuver drums without relying exclusively on forklifts, reducing both the frequency of equipment use and the chance of related accidents. Features such as lift loops, dolly straps, and reinforced zippers further enhance safety by giving workers more control during handling.
Another critical safety benefit comes from the collapsible design. Traditional gallon barrels clutter storage areas and create obstacles that increase the risk of slips, trips, and falls. Gorilla Drums, when collapsed, minimize clutter and make storage areas cleaner and more organized, directly lowering accident rates. Safer environments also mean fewer workers’ compensation claims and less downtime, reinforcing the financial benefits of switching.
Lined vs. unlined steel drums
When businesses buy 55 gallon drums, they often face a choice between lined and unlined models. Lined drums are coated with epoxy or phenolic resins to prevent contents from reacting with the raw steel, making them suitable for corrosive or sensitive materials. Unlined drums, in contrast, are bare steel inside and used for non-corrosive substances like oils or lubricants.
While both designs have their place, they share the same fundamental problems: weight, rigidity, and eventual failure. Lined drums extend service life but do not eliminate corrosion risk. Once the coating breaks down, the drum must be retired or replaced. Unlined drums may last longer with certain materials, but their applications are limited, and they remain heavy and space-inefficient.
Gorilla Drum eliminates the need to choose between lined and unlined options. Its polypropylene construction resists corrosion naturally, without coatings that wear away over time. The same container can handle a wide range of materials, both hazardous and non-hazardous, without requiring businesses to purchase separate drum types for different applications. This versatility reduces inventory complexity, streamlines procurement, and cuts costs further.
Long-term operational advantages
Beyond immediate cost and safety benefits, Gorilla Drum contributes to broader operational improvements. Its efficiency in storage and transportation reduces the need for additional warehouse facilities, lowers freight emissions, and helps companies meet sustainability goals. Its recyclable construction also supports environmental initiatives, giving businesses a container solution that aligns with growing regulatory and customer demands for greener practices.
For workers, Gorilla Drum creates a safer and more ergonomic environment, reducing injury rates and improving morale. For managers, it delivers greater control over logistics, with fewer inefficiencies and lower risks of compliance issues. For financial teams, it translates into quantifiable savings in shipping, storage, labor, and replacements.
In short, Gorilla Drum provides a comprehensive solution that extends beyond being an alternative container—it is a strategic asset for modern businesses seeking efficiency, safety, and sustainability.
Final thoughts
The fifty five gallon drum has served industries well for decades, but its limitations in cost, safety, and efficiency make it increasingly outdated. Steel drums are heavy, prone to corrosion, and costly to transport. Plastic drums, while resistant to rust, remain rigid and inefficient. For companies seeking to buy 55 gallon drums today, the smarter investment is not in traditional gallon barrels but in modern, collapsible alternatives.
Gorilla Drum provides the same capacity as a 55 Gallon Barrel but with added benefits: collapsibility, recyclability, ease of handling, and compliance with hazardous material standards. Businesses that switch see immediate savings in storage and transport while improving safety for their employees.
For more information on how Gorilla Drum can help your business replace outdated 55 Gallon Drum Containers, call +1 800-758-8079 today.