The limitations of standard 55 gallon barrels
Before exploring why Gorilla Drum is the superior option, it’s important to understand the challenges of traditional drums. A 55 Gallon Barrel Metal container is heavy, weighing more than 40 pounds when empty. It takes up the same space whether full or empty and is prone to dents, rust, or corrosion. Even a Plastic 55 Gallon Drum, while lighter, suffers from similar storage inefficiencies because it cannot collapse. Companies that buy 55 gallon drums repeatedly encounter higher transportation costs, wasted warehouse space, and disposal issues.
These shortcomings are what drive businesses to seek alternatives that reduce costs and improve safety while still offering the familiar 55-gallon capacity.
What is the alternative to the 55 gallon drum?
For decades, businesses had little choice beyond the standard steel or plastic 55 Gallon Drum. These gallon barrels became so widespread because of their durability and compatibility with shipping systems worldwide. But with time, the limitations of the traditional 55 Gallon Barrel have become clear: they are heavy, rigid, and inefficient when it comes to transportation and storage. This has created a growing demand for alternatives that solve the problems inherent in a 55 Gallon Barrel Metal or plastic container.
The modern alternative is Gorilla Drum, a collapsible polypropylene 55 Gallon Drum Container that is revolutionizing the way industries think about bulk storage and transportation. Instead of weighing over 40 pounds like a steel drum, Gorilla Drum weighs only about 7.5 pounds unfilled, making it much easier and safer to handle. Despite being lighter, it maintains the same fifty five gallon drum capacity and meets stringent UN/DOT certification standards, ensuring it is suitable for hazardous and non-hazardous materials alike.
One of the most compelling advantages is collapsibility. Traditional 55 Gallon Steel Drums and Plastic 55 Gallon Drums take up the same amount of space regardless of whether they are in use. Gorilla Drum, on the other hand, can be collapsed flat, which means up to 80 units fit on a single pallet and more than 4,000 can fit into a truckload. This represents a twenty-fold improvement in shipping efficiency compared to rigid gallon barrels, significantly lowering freight costs and reducing carbon emissions.
Another key benefit is safety. Gorilla Drum is designed with practical features like lift loops, a dolly strap, reinforced zippers, a belly band, and a labeling window. These additions make it easier for workers to move, secure, and identify the container. By comparison, moving a heavy 55 Gallon Steel Drum often requires forklifts, which increases the risk of accidents. Lightweight alternatives minimize these risks while still providing the durability needed for demanding industries.
For companies that regularly buy 55 gallon drums, shifting to a collapsible alternative translates into long-term cost savings, safer workplaces, and greater sustainability. Businesses no longer need to choose between compliance and efficiency—they can have both. Gorilla Drum represents the next evolution in gallon barrels, offering the familiar capacity of a 55 Gallon Barrel but with innovative design that solves the challenges steel and plastic drums have created for decades.
For a comprehensive breakdown of options, see the Complete Guide To Choosing The Right 55 Gallon Drum Alternative.
Are 55 gallon drums considered bulk?
In many regulatory and logistical contexts, a 55 Gallon Drum is considered bulk packaging. This is because of its capacity, which meets or exceeds the threshold that defines bulk storage for hazardous and non-hazardous materials. A fifty five gallon drum typically holds 208 liters, a volume significant enough to be regulated differently than smaller containers such as pails or jerricans. This classification has practical implications for how these gallon barrels are handled, transported, and labeled.
From a compliance perspective, the Department of Transportation (DOT) and other regulatory bodies categorize packaging as bulk when it meets certain volume thresholds. Since a 55 Gallon Drum Container exceeds those limits, it is treated as bulk packaging for the purposes of labeling, placarding, and shipping documentation. For companies that buy 55 gallon drums, this means they must adhere to stricter standards compared to businesses using smaller containers. Whether it is a 55 Gallon Steel Drum or a Plastic 55 Gallon Drum, the same rules apply.
The bulk classification also influences how these containers are moved within facilities. A 55 Gallon Barrel Metal option often requires forklifts, drum handlers, or pallets to move safely, adding to labor costs and safety concerns. Workers must be trained in how to secure, strap, or stack these drums to prevent accidents. Even seemingly small missteps—like stacking drums improperly—can lead to spills or damage that create compliance risks. This is one of the key reasons companies look for alternatives to gallon barrels that reduce the need for heavy lifting or complex handling.
Another consideration is the impact on transportation efficiency. When classified as bulk, gallon barrels must be secured to prevent shifting during transit. They also demand specific vehicle configurations to comply with regulations. A truckload of 55 Gallon Steel Drums, for instance, typically maxes out at about 208 units, consuming significant space and weight allowances. Gorilla Drum changes this equation by collapsing when empty, allowing over 4,000 units per truckload. While still technically bulk packaging when filled, its collapsibility eliminates many of the inefficiencies that plague traditional 55 Gallon Barrel shipments.
For industries that rely on bulk packaging, Gorilla Drum demonstrates that capacity and compliance don’t have to come with unnecessary costs. By maintaining the same volume as a standard drum while reducing handling risks and transportation waste, it offers a practical and forward-thinking solution for businesses that depend on bulk containers every day.
How much is actually in a 55 gallon drum?
At first glance, the name seems to answer the question directly: a 55 Gallon Drum holds 55 gallons. In reality, though, the usable capacity of a fifty five gallon drum can vary depending on design, contents, and regulations. While these containers are standardized across industries, the exact amount of liquid or solid material they can safely contain is often a little less than the stated figure.
The standard volume of a 55 gallon drum
By definition, a 55 Gallon Barrel has a nominal capacity of 55 U.S. gallons, or approximately 208 liters. This measurement has been widely adopted in logistics and industrial applications worldwide. The consistency of size allows drums to be stacked, stored, and shipped on pallets and within truckloads with predictable efficiency. However, the “55 gallons” figure does not always reflect the amount a drum is filled with during actual use.
Headspace and fill levels
Most 55 Gallon Drum Containers are not filled to the top. Instead, manufacturers and shippers leave headspace, which is the empty room between the liquid level and the drum’s closure. This extra space allows for expansion of liquids due to temperature changes during storage or transit. Without it, contents could expand, creating dangerous pressure or spills. For this reason, the actual usable capacity may be closer to 52–54 gallons, depending on the product.
Weight capacity versus volume
Another consideration is weight. A 55 Gallon Steel Drum may be rated to hold several hundred pounds, while a Plastic 55 Gallon Drum may have a different weight tolerance. For instance, water weighs about 8.34 pounds per gallon. A completely filled drum of water could weigh over 450 pounds, not including the drum itself. When dealing with heavier liquids like oils, chemicals, or dense slurries, the safe fill weight may be the limiting factor rather than pure volume. This is why the weight rating is just as important as the stated volume when evaluating gallon barrels.
Design variations that impact capacity
Not all 55 Gallon Barrels are built identically. Some are open-head designs with removable lids, making them ideal for solids or semi-solids. Others are closed-head designs with bung openings, optimized for liquids. The shape of the head, wall thickness, and lining can all slightly affect how much usable product fits inside. While the nominal size remains 55 gallons, the practical capacity may shift depending on these design elements.
Gorilla Drum’s tested capacity
When compared to standard gallon barrels, Gorilla Drum maintains the same 55-gallon capacity but with a few notable improvements. It has a tested safety factor of 6:1 and can hold up to approximately 452 pounds of material. It has also been stack tested to 1,000 pounds, ensuring that capacity isn’t just theoretical but safe in real-world use. By matching the expected volume of a 55 Gallon Barrel Metal or plastic container while improving handling and logistics, Gorilla Drum ensures businesses get the capacity they need without the drawbacks of heavy, rigid designs.
The importance of knowing the true capacity
For businesses purchasing a 55 gallon drum for sale, understanding how much product can actually fit inside is critical. Overfilling leads to spills, regulatory issues, and damaged goods. Underfilling reduces efficiency. By accounting for headspace, weight limits, and the design of the container, companies can make informed decisions about how best to store and transport their products. Gorilla Drum makes this easier by combining the reliability of a fifty five gallon drum with the efficiency of a collapsible alternative.
Efficiency gains with Gorilla Drum
Gorilla Drum offers businesses measurable gains:
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Space savings: Collapsible design allows thousands more units per truckload compared to rigid gallon barrels.
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Weight reduction: At only 7.5 pounds unfilled, it is significantly easier to handle than a steel or plastic drum.
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Handling improvements: Lift loops, dolly straps, and reinforced zippers make it safer and faster to move.
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Sustainability: Made of recyclable polypropylene, reducing environmental impact compared to steel or plastic alternatives.
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Cost reduction: Lower transportation expenses and storage costs create long-term financial savings.
These benefits prove why Gorilla Drum is the next step beyond traditional 55 Gallon Barrel options.
Why standard drums are being phased out
Businesses that buy 55 gallon drums regularly face compounding inefficiencies. Warehouses filled with bulky gallon barrels pay more for space, while fleets shipping heavy drums spend more on fuel. Even disposal comes at a cost, as steel and plastic drums require proper recycling or waste processing. Gorilla Drum solves these pain points by combining compliance, efficiency, and sustainability.
As companies prioritize reducing emissions and improving logistics, rigid drums are becoming less practical. Gorilla Drum ensures that businesses no longer have to compromise between capacity and efficiency.
Industry applications
Gorilla Drum is used in industries that previously relied on steel or plastic gallon barrels, including:
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Waste management and hazardous materials: Certified for hazardous liquids and multiple classes of dangerous goods.
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Shipping and logistics: Major package handlers have already adopted Gorilla Drum to save space and cut costs.
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Laboratories and healthcare: Safer handling for sensitive materials without the risk of corrosion.
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Food and beverage: Collapsible containers that protect products while improving supply chain efficiency.
These applications show how Gorilla Drum outperforms the 55 Gallon Steel Drum or Plastic 55 Gallon Drum in nearly every environment.
Long-term cost and safety advantages
Switching from traditional gallon barrels to Gorilla Drum isn’t just a logistical improvement—it’s also a safety and cost advantage. Workers avoid the risks of moving heavy, rigid containers. Businesses save money on storage and transport. Environmental goals are met with recyclable materials. For organizations weighing whether to continue with a 55 Gallon Barrel Metal container or modernize, the decision is clear.
Final thoughts
The fifty five gallon drum has served industries for decades, but its limitations in weight, space, and handling make it increasingly outdated. Gorilla Drum provides the same 55-gallon capacity while offering collapsibility, recyclability, and efficiency that traditional steel and plastic drums cannot match. For businesses that rely on gallon barrels, Gorilla Drum is the smarter, safer, and more sustainable solution.
To learn more about why Gorilla Drum outperforms standard 55 Gallon Barrels and how it can fit into your business operations, call +1 800-758-8079 today.