This article contains everything you will need to know about poly tanks and their use.
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Poly tanks are adaptable containers crafted from plastic, specifically engineered for storing, transporting, and collecting water, liquids, and powdered or granular materials. Made from either polyethylene or polypropylene, these tanks are lightweight, cost-effective, and easily managed, making them perfect for handling substantial volumes of materials.
For decades, storage tanks have been crucial in industrial settings due to their strength, durability, and ease of use. With the introduction of poly tanks, the storage landscape has transformed, offering an impressive blend of reliability and longevity. While metal tanks continue to serve important roles in certain areas, poly tanks increasingly set the standard for contemporary storage needs.
Even though poly tanks are very stable, they require an appropriate foundation for support. Suitable materials for this base include crushed gravel, sand, wood chips, or other firm substances to keep the tank securely in place. Typically, with normal use, poly tanks can have a lifespan reaching up to 20 years, as they are designed with UV stabilizers to prevent sun damage. They need minimal maintenance and can be fitted with self-cleaning systems to clear out debris that may accumulate at the bottom.
Poly tanks, short for polyethylene storage tanks, are engineered to safely store a wide variety of liquids. These plastic tanks are categorized by polyethylene grade, intended storage application, tank orientation, and additional features. The two primary categories are potable poly tanks, designed and certified for drinking water storage, and non-potable poly tanks, which store other liquids such as greywater, chemicals, fertilizers, and industrial fluids.
Vertical poly tanks, also known as upright polyethylene storage tanks, are the most common tank design and are highly valued for their space-saving footprint and superior strength. These vertical storage tanks are frequently used for storing water (including rainwater harvesting), caustic chemicals, agricultural fertilizers, and fuels. Their upright, cylindrical construction promotes uniform distribution of hydrostatic pressure, reducing stress points and increasing longevity for bulk liquid storage.
The manufacturing process for these tanks uses rotational molding (rotomolding) to create a seamless, robust, and impermeable barrier. This ensures resistance to cracking, corrosion, impacts, UV degradation, and extreme temperatures. Food-grade and FDA-approved vertical poly tanks are essential for applications in food processing, beverage manufacturing, and the pharmaceutical industry. Tank customization is available, with options including threaded and bolted fittings, sight gauges, manways, insulation jackets, heating pads, external ladders, and internal baffles to control fluid movement and mixing.
Compared to horizontal poly tanks, vertical tanks are designed for larger storage capacities and increased durability, making them ideal for farm irrigation storage, industrial process water, chemical containment, acid storage, and fire protection systems. Certain models can safely accommodate aggressive chemicals, such as sulfuric acid and sodium hypochlorite, due to specialty resin and thicker wall design.
Horizontal poly tanks, often called leg tanks or transport tanks, feature a low-profile design with molded support legs or cradles. These tanks are highly portable, facilitating easy movement by forklifts, trucks, tractors, or mounted trailers, which is especially useful for mobile water storage and liquid chemical transport. They are commonly utilized as nurse tanks for agricultural spray rigs, livestock watering, graywater collection, and portable fuel storage.
Unlike vertical tanks, horizontal poly tanks are designed with increased stability for mobile applications and minimal sloshing during liquid transit. Their translucent construction, along with molded-in calibration markings, enables easy visual inspection of fluid levels. Typical features include manway access at the top, pressure/vacuum relief vents, and bottom drain outlets for complete drainage. The compact, oblong design is especially valuable where headroom or ground clearance is limited, such as under decks or in vehicle beds.
Industry-specific applications range from liquid fertilizer batching and defensible space firefighting to potable water supply on construction sites. Available shapes include conventional elliptical, rectangular, and DOT-compliant transport models to suit regulatory requirements and operator safety considerations.
Underground poly tanks, sometimes referred to as poly cisterns or below-ground water storage tanks, are designed for discreet installation beneath the surface. They provide solutions for rainwater harvesting, emergency water supply, septic holding, and stormwater management where above-ground space is scarce or local ordinances prohibit visible tanks. Underground poly tanks can store thousands of gallons, with some models reaching 20,000 gallons or more.
These tanks are rotationally molded for seamless water-tightness and resistance to soil chemicals, root intrusion, and fluctuating ground conditions. After installation, risers provide surface-level access for inspection, maintenance, and pump servicing. Poly cistern tanks and underground water tanks must comply with local plumbing codes and NSF/ANSI standards for potable water use, making them suitable for residential, agricultural, and municipal projects.
Proper installation entails excavating an appropriately sized hole, prepping a granular drainage bed with gravel or coarse sand, and ensuring a level base to prevent settling or shifting. Options include tanks with integrated pump chambers, inlet/outlet connections for irrigation systems, stormwater bypass, and single- or dual-compartment designs for graywater or blackwater separation. Underground plastic tanks are often insulated to prevent freezing and algae growth.
Silo poly tanks are specially engineered with a conical bottom, which enables efficient gravity-fed dispensing of dry goods, grains, pellets, powders, or bulk liquids. These conical tanks are integral in grain storage, seed handling, feed dispensing, and chemical mixing systems. Due to the added stress of heavy stored material, silo poly tanks require robust steel framework and support stands to uphold safety standards and prevent collapse.
The elevated structure, with measured clearance beneath the cone, streamlines material discharge into augers, conveyor belts, or packaging equipment. Typical capacities range up to 10,000 liters (approximately 2,650 gallons), with models designed for rapid filling via large top hatches. Available add-ons include level indicators, integrated valves, quick-connect outlets, dust control lids, and anti-static coatings for powders.
Chemical poly tanks, essential for industrial chemical storage and hazardous waste management, are designed for the safe and compliant containment of acids, alkalis, wastewater, and volatile liquids. Their high chemical resistance, lightweight profile, and versatility have made them the storage solution of choice for many industries, including manufacturing, water treatment, mining, and food processing.
Industry-leading chemical tanks utilize corrosion-resistant resins such as cross-linked polyethylene (XLPE) to withstand harsh chemicals like hydrochloric acid and sodium hypochlorite. Double-wall and secondary containment features provide extra spill protection, aligning with EPA, NSF, and UL storage regulations. Manufacturers frequently offer certification to verify compliance with stringent environmental and occupational safety standards.
Maintaining chemical poly tanks involves periodic inspections, safe discharge procedures, and rigorous cleaning protocols. Couplings, venting systems, flange outlets, and leak detection equipment are typically standard. The seamless, one-piece construction ensures secure, leak-free containment, and the vertical configuration maximizes capacity. Chemical tanks with double-wall construction are a best practice for areas subject to regulatory audits or environmental risk considerations.
Poly septic tanks, or polyethylene septic systems, provide reliable, corrosion-resistant underground wastewater management for residential, rural, and commercial properties. These tanks are engineered to withstand soil loading, effluent gases, and aggressive chemicals, outperforming concrete and metal septic tanks in chemical resistance and installation ease.
The single-piece, seamless construction ensures watertight integrity, minimizing the risk of groundwater contamination. Delivered pre-plumbed, poly septic tanks reduce installation time and cost and are easy to maneuver and relocate due to their lightweight build. With flexible placement and suitability for difficult access sites, they are ideal for new builds, retrofits, cabins, and off-grid living.
Cost-effective and durable, poly septic tanks offer prolonged service life and low maintenance requirements. They are typically installed on a prepared gravel bed to facilitate drainage and prevent tank floatation. Some models include multiple chambers to improve solids separation and treatment efficiency.
RV poly tanks are a specialized category of polyethylene storage tanks designed for recreational vehicles, boats, and mobile applications. Common purposes include RV water tanks for fresh water delivery, graywater tanks for sink and shower drainage, and holding tanks for blackwater/waste. These tanks must meet NSF/ANSI and FDA standards for potable water and food contact safety.
Most RV poly tanks are rectangular or custom-shaped to optimize space in vehicle compartments, and are produced with seamless, single-piece construction to prevent leaks and contamination. Their compatibility with 12V water pumps, gravity-feed systems, and RV plumbing fixtures makes them essential for self-contained mobile plumbing. Accessories may include tank monitors, quick-drain valves, and inline filters to ensure reliability.
The diversity of sizes and modular options allows RV owners to tailor their water and waste storage solutions for long trips, boondocking, or marine use. Easy installation, lightweight design, and corrosion resistance are crucial benefits for vehicles frequently exposed to vibration, weather, and road chemicals.
Rectangular poly tanks, sometimes called box tanks, are popular for their adaptable shapes and efficient space utilization. They are widely used for water storage, chemical containment, aquaponics, sump pits, brine storage, and process tanks in laboratory and industrial settings.
These plastic tanks may feature open-top or closed-lid designs—open-tops are excellent for mixing, cleaning, or dipping operations, while closed-lid rectangular tanks ensure contained, contaminant-free fluid storage. Stackable capabilities maximize vertical space in warehouses or tight equipment rooms. Rectangular tanks are preferred for applications requiring maximum volume in a given footprint, such as under-deck storage or modular water management systems.
Accessories such as bulkhead fittings, sloped bottoms for drainage, baffles for slosh control, and reinforcement ribs are available to meet rigorous industrial needs. These tanks can be manufactured from high-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), or other resins, depending on chemical compatibility requirements.
Poly water tanks—commonly called plastic water tanks, potable water tanks, or polyethylene water tanks—are the backbone of residential, agricultural, fire suppression, and commercial water storage. Built for chemical resistance, impact durability, and long service life, poly water tanks deliver clean, safe, and reliable water supply to homes, farms, ranches, and remote locations.
These storage tanks are available in both horizontal and vertical forms, with capacities ranging from 50 gallons to more than 50,000 gallons to support applications from rainwater collection and irrigation to drinking water reserves and livestock watering. Poly water tanks are manufactured in colors like green, black, and dark brown for ultraviolet light resistance, which limits algae growth by blocking sunlight—an important feature for long-term water storage tanks.
Specific gravity ratings determine which liquids each tank can safely hold: a rating of 1.0 suits potable water storage, while higher ratings are available for more dense or viscous fluids. Wall thickness, resin grade, and tank design are tailored for demanding conditions, such as severe temperature swings or exposure to corrosive environments.
In addition to agricultural and household uses, poly water tanks play a critical role in firefighting tanks, rainwater harvesting systems, stormwater retention, and backup emergency water supplies. Tank sizes and configurations are chosen based on daily usage needs, available site space, regulatory codes, and delivery logistics. Accessories include float valves, sight tubes, overflow protection, autofill kits, and anti-vortex assemblies for efficient operation.
For above-ground and below-ground installations, rotationally molded poly tanks provide seamless construction, integral strength, and longevity. Underground models prevent sunlight intrusion and are insulated or buried below frost lines to avoid freezing. All potable water tanks must be certified to NSF/ANSI Standard 61 or an equivalent for drinking water safety.
Choosing the right poly water tank size requires consideration of intended use, available installation space, frequency of filling, and transportation needs. Large capacity tanks (10,000–50,000 gallons) reduce refill frequency and are ideal for central water supply, fire protection reserves, and community rainwater collection. Smaller tanks are easier to manage and move for gardening, mobile applications, or temporary storage.
Benefits of Larger Poly Water Tanks
Smaller Poly Water Tank Advantages
Underground poly water tanks offer discreet water storage and solve challenges where above-ground installation is not feasible. Their insulated, UV-blocking properties reduce the risk of algae and microbial growth, ensuring high water quality for long-term potable water storage. Most underground tanks are rated for use as potable water cisterns and include pump and piping systems for reliable dispensing. Proper installation below the frost line prevents freezing, with tanks ranging from small 200-gallon units to large multi-thousand-gallon designs.
With advances in polyethylene resin technology and rotational molding, poly tanks can now be custom-fabricated for highly specific needs, such as industrial chemical processing, hazardous liquid containment, salt brine storage, and even aquaculture operations. Leading manufacturers work closely with end users to design and engineer tanks with precise dimensions, connection fittings, level monitoring systems, insulation layers, and other application-specific accessories—ensuring every plastic tank solution is tailored for maximum efficiency, regulatory compliance, and longevity.
One of the key attributes of poly tanks is their seamless, solid walls, which ensure leak prevention and impact resistance. Unlike standard plastic products, which may use various molds that are either permanent or temporary with melted resin poured into them, poly tanks require specialized manufacturing processes. These techniques are designed to create large containers with thicker, more resilient walls to meet the demands of their size and durability.
Rotational molding and blow molding are the primary techniques employed in the production of poly tanks, as both methods utilize large molds. Poly tanks are made from two main polymers: polyethylene and polypropylene, both of which offer robust and durable properties essential for manufacturing these tanks.
Rotational molding, or roto molding, is commonly used to manufacture large poly tanks with substantial capacities. This process involves three main steps: heating the mold while it rotates. The rotation ensures that the plastic resin is distributed uniformly across the mold's surface. During the process, the resin is added to the mold in granular form and melts as the mold is heated.
At the workstation, which may be elevated for convenient access, a worker adds a precisely measured amount of resin into the mold. This resin, which is dry, fine, and consistent, ensures smooth flow and prevents bubble formation in the poly tank's walls. The measured amount of resin directly affects the thickness and strength of the tank's walls, ensuring the final product meets the required specifications.
To facilitate the easy removal of the finished poly tank, a release agent is applied to the inside of the mold. This mold, typically crafted from cast metal, is designed with the exact shape and dimensions of the final poly tank to be produced.
Once the resin-filled mold is securely sealed, it is transferred to a furnace where it will be heated. The mold then starts rotating on multiple axes as it exits the workstation, ensuring that the resin is evenly distributed across the mold's interior. The wall thickness is determined by the mold's rotation speed, with a specific ratio of rotations per minute (RPM) on the horizontal axis compared to the vertical axis. This rotational ratio is carefully adjusted based on the poly tank's shape, as different shapes like spheres or cubes require different ratios for optimal results.
Heating time for poly tanks is adjusted based on the specific shape and type of tank being produced. Accurate control of heating time is crucial for ensuring the final product's quality, as both overheating and underheating can lead to defects in the poly tank.
During the cooling phase, the poly tank solidifies into its final shape. As the resin hardens on the mold's walls, it's essential to apply cooling air gradually to prevent rapid cooling, which could distort the tank. For some designs, water may be sprayed to expedite the cooling process, but this must be carefully managed to ensure it doesn’t compromise the tank’s properties or dimensions.
Similar to the heating process, the cooling period is carefully regulated to match the size and type of the poly tank. Proper cooling rates are crucial, as either too rapid or too gradual cooling can compromise the structural integrity of the tank, affecting its quality.
Once the poly tank has cooled sufficiently, it is moved back to the workstation for removal from the mold. An air ejection system aids in this process by pushing the tank out of the mold. After demolding, the tank undergoes an inspection to check for wall uniformity, bubbles, distortions, or other defects. Being a single-piece mold, poly tanks do not require further division. Additional processing may involve cutting openings for flanges, fittings, connections, lids, or other custom modifications as needed.
Blow molding is another method used for creating poly tanks and can manufacture tanks of various sizes, including those much larger than those made by rotational molding. Like rotational molding, blow molding also utilizes molds, which can range from small containers like trash cans to large tanks designed for underground use. This technique is commonly employed for producing clear plastic bottles and containers in large quantities.
Creating large poly tanks involves a more extended production process but allows for the manufacture of tanks with high precision. Blow molding, like rotational molding, consists of three main stages, but it also includes an extra step where the resin is melted and heated prior to being injected into the mold.
In blow molding, the resin undergoes a heating and melting phase before being introduced into the mold. This part of the process is comparable to other molding techniques and utilizes an extruder, which includes a hopper, a screw, heaters, a barrel, and a nozzle. Resin is gradually fed into the barrel from the hopper. As the screw rotates, it pushes the resin along the barrel, where it is heated until it becomes molten and ready for molding.
During the blow molding process, the extrusion phase creates a flexible, inflated preform known as the parison. This parison, shaped like a closed-end tube and resembling a large cylindrical balloon, is produced by the nozzle at the end of the extruder. As the parison is formed, its wall thickness is carefully controlled to ensure that when it expands within the mold, the resulting poly tank will have uniform and smooth walls.
The extrusion head plays a crucial role in managing the wall thickness of the poly tank through its conical design. By adjusting the position of the mandrel and the conical outer ring of the extrusion head, the thickness of the parison can be precisely controlled. This allows for the final poly tank to achieve the desired wall thickness, ensuring uniformity in the finished product.
After the parison is shaped and ready, it is inserted into the die, which consists of two halves that are securely clamped together. Ensuring a tight seal of the die is crucial to avoid any gaps and to guarantee the even distribution of the parison throughout the mold. Proper spreading of the parison is vital for achieving uniform wall thickness in the final poly tank.
Blow molding dies come in a vast range of sizes, allowing for the production of poly tanks ranging from just a few gallons to several thousand gallons. While smaller dies are relatively easy to handle, larger dies resemble heavy-duty forging presses due to their substantial size and complexity.
In the blow molding process, pressurized air is introduced into the parison, causing it to expand swiftly and conform to the mold's walls. To ensure uniform wall thickness, the air must be applied evenly. Similar to the heating phase in rotational molding, the air pressure in blow molding is meticulously regulated to prevent excessive stretching of the parison.
In the case of square or rectangular poly tanks, air is often distributed through multiple orifices to achieve consistent airflow, as the angles and corners of these molds can be challenging to reach. By using several air channels, the parison is effectively pushed into the corners and edges of the tank, ensuring a thorough and even fill.
The final stage in the blow molding process involves cooling and solidifying the poly tank. Unlike rotational molding, where the entire mold is heated, blow molding primarily heats only the parison. Consequently, the cooling phase for blow molding is generally shorter, although it remains the most time-consuming part of the procedure. Cooling starts as soon as the air is applied and continues throughout the molding process.
During the cooling phase of blow molding, the heat from the parison is conducted to the interior surface of the mold. One challenge in this stage is managing the residual heat trapped inside the poly tank. To address this, internal cooling systems are employed, ensuring a safe and effective method to expedite the cooling process.
Similar to roto molding molds, blow molding molds consist of two halves that separate once the poly tank has cooled adequately. After removal from the mold, the poly tank undergoes a thorough inspection to check for any deformations or leaks, a crucial step particularly for large tanks that hold hundreds or thousands of gallons.
Poly tanks are made from resins derived from petroleum, commonly referred to as polymers or plastics. These terms encompass a broad spectrum of plastic materials with diverse grades, types, strengths, and chemical compositions. Each type of plastic is chosen for its specific properties, making it suitable for different applications in plastic manufacturing.
Poly tanks are primarily made from two widely used polymers: polyethylene and polypropylene. These versatile materials are employed globally in a variety of products, including clothing hangers, beverage bottles, and durable equipment casings. Their robustness and adaptability make them ideal for manufacturing poly tanks and numerous other applications.
Polyethylene, often abbreviated as PE, polythene, or polyethene, is produced through the polymerization of ethylene (C2H4), an organic hydrocarbon. This process involves adding titanium chloride and high molecular weight nonpolar saturated hydrocarbons. The result is a crystalline plastic with properties similar to paraffin. Polyethylene's molecular structure, which lacks cross-linking, contributes to its high density and chemical stability.
Polyethylene comes in various forms, including low density (LDPE), linear low density (LLDPE), linear medium density (LMDPE), high density (HDPE), ultra high molecular weight (UHMWPE), and cross-linked (PEX). While all these types have their uses in manufacturing, poly tanks are primarily made from PEX, LMDPE, and HDPE. These specific types are chosen for their superior mechanical strength, durability, and resistance to environmental conditions.
Among the various materials used for manufacturing poly tanks, polypropylene—also known as propene, PP, or propylene—is particularly versatile. This plastic can be utilized in a range of applications, including textiles, packaging, and poly tanks. It is produced through the polymerization of the propene monomer using either the Ziegler-Natta process or metallocene catalysis. Polypropylene features a crystalline structure that provides it with flexibility, durability, chemical resistance, and the ability to withstand temperature fluctuations. It is part of the olefin family of double-bonded hydrocarbons. During polymerization, the propene molecules undergo bond rearrangement to form the polypropylene polymer chain.
Polypropylene stands out for its exceptional chemical resistance, ability to endure temperature fluctuations, and high level of purity. Its robust strength and durability make it a suitable choice for producing containers, including poly tanks.
Polyvinyl chloride, or PVC, comes in flexible and rigid forms, depending on the additives used. Renowned for its remarkable mechanical properties, PVC is well-suited for demanding environments requiring durable materials. Its strength rivals that of many metals, which is why it's commonly used in plumbing applications. PVC is primarily composed of chlorine, derived from salt, combined with carbon and hydrogen. It is manufactured from vinyl chloride monomer, which is produced through the chlorination of ethylene and pyrolysis, followed by polymerization to create PVC.
PVC, a thermoplastic, becomes pliable when heated, allowing it to be molded into poly tanks. The rigid variant of PVC is utilized in the production of these tanks, offering a high-density material that is both impact-resistant and chemically durable.
Poly tanks have long been utilized for water storage and the transportation of chemicals like pesticides and fertilizers. Their popularity in agriculture stems from their durability, strength, and ease of movement. The lightweight nature of poly tanks allows for flexible placement in various locations, reducing the risk of cracking or leaking.
Poly tanks are often preferred over metal tanks primarily because of their lower cost. This affordability is attributed to the inexpensive raw materials required for their production, as well as the more efficient manufacturing processes involved. Consequently, poly tanks offer a cost-effective alternative to metal tanks.
Poly tanks, being lightweight, can be effortlessly placed without the need for specialized support. Installing underground poly tanks is simpler compared to concrete alternatives. Their sturdy construction ensures leak prevention, and the poly material remains unaffected by soil chemicals.
Another advantage of poly tanks is their ease of handling due to their lightweight nature. They can be moved or repositioned without the need for heavy machinery or specialized tools. This flexibility is particularly useful for companies undergoing expansion or renovations, as poly tanks can be emptied, lifted, and relocated as needed to adapt to new requirements.
Poly tanks come in a vast array of sizes, colors, shapes, and designs, making them suitable for a wide range of industrial applications and spatial requirements. Additionally, manufacturers collaborate with clients to create customized poly tanks tailored to specific and unique needs, ensuring versatility and adaptability for various situations.
The variety of poly tank designs and colors allows them to be seamlessly integrated into the architectural aesthetics of a building, a flexibility not typically found with other types of storage tanks. Often, architects incorporate poly tanks into their designs, taking advantage of their adaptability to meet specific architectural needs.
Poly tanks are renowned for their robust durability, making them ideal for challenging environments where they store water and chemicals. Unlike some metals, poly tanks resist rust and are immune to varying weather conditions. They are designed to withstand extensive use over many years with minimal maintenance and do not require specialized cleaning procedures.
Poly tanks are certified by the FDA and EPA for storing and transporting potable water. Their construction materials are highly hygienic and sanitary, making them a popular choice in the food and pharmaceutical sectors for their reliability and cleanliness.
Given the diverse range of liquids stored in poly tanks, regulatory bodies such as the FDA, EPA, NSF, and ANSI have established guidelines and standards for their production. These regulations primarily focus on the safe storage of potable water and food products, ensuring that any fluids or liquids in contact with humans meet strict safety and hygiene requirements.
Given the extensive use of poly tanks for potable water storage and transportation, various regulatory agencies have set specific requirements. The polyethylene used in these tanks must be inert, ensuring it does not leach chemicals or react with the water. Manufacturers must hold certifications from the Environmental Protection Agency (EPA), the Food and Drug Administration (FDA), the Code of Federal Regulations (CFR), the National Sanitation Foundation (NSF), and the American National Standards Institute (ANSI), which are typically indicated on their products.
Poly tanks are required to be built to endure the pressure exerted by the stored water. This includes specifications for wall thickness and uniformity, which are assessed and verified during production. While manufacturers may use various types of resins, they all ensure that the resins comply with relevant regulatory and organizational standards.
Title 21 of the FDA and CFR outlines the standards for poly tanks used in food and beverage storage and processing. This section details the permissible resins, additives, and the construction specifications for these tanks. Poly tanks are preferred for their single-piece, seamless design, which enhances safety and dependability compared to other tank types.
Section CFT 1250.82 of Title 21 specifies the standards for poly tanks intended for potable water. These regulations cover aspects such as drainage, overflow management, venting, and techniques for gauging water depth. A key focus of these standards is to prevent any potential backflow that might lead to contamination of the stored drinking water.
Regulations governing poly tanks vary across different sectors, with a particular focus on those used in industrial settings. The primary concern is safety, ensuring that water remains uncontaminated and chemicals are securely contained to prevent leaks. Different organizations establish detailed guidelines for both above-ground and below-ground installations, with the latter requiring more stringent and rigorous standards.
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