Production Process

Jumbo Bags/ FIBC Production Process

The FIBC / Bulk Bags are generally manufactured and printed as per customer’s requirement. The end users adopt different kinds of color combinations and designs in the printing of these products to convey the massage(s), characteristic(s), quantity &quality related details and handling instructions etc. For some kind of specific applications like filling of hydroscopic materials e.g. chemicals, fertilizers, food products etc.

The process of manufacturing FIBC / Bulk Bags involves following three steps:

Stage -1, Extrusion

This process converts the PP raw with all additives necessary for this process (antistatic, light and UV stabilizing, coloring pigments and fillers mixed in different proportions to suit client order and specifications) into tape of different thickness, weight and tensile strength.

This tape extrusion is then rolled on bobbins through winders and segregated by colors and all other criteria to form the pillar stock necessary weaving to other processes.

Stage -2, Weaving and Coating

Using the tape bobbins , weaving machines convert them into fabric that meets client order for weight per square meters, color and dimensions. The fabric rolls are then stocked and labeled by order number prior to sending them for finishing. Required loops, belts and tie tapes also be produced during this stage by using needle looms.

Coating facility will be used when required by order to treat and coat the fabric for sealing and strengthening it prior to its final finishing.

Stage -3, Finishing

During finishing stage, Bags form as per customer requirement by completing cutting, printing and stitching process. Desired printing can be fulfilled at this stage. Quality approved bags will move in to packing division

Container Liners

The Container Liners are generally manufactured and printed as per customer’s requirement. The end users adopt different kinds of color combinations and designs in the printing of these products to convey the massage(s), characteristic(s), quantity &quality related details and handling instructions etc.…

Same process for FIBC is followed for extrusion and weaving. Further,

Webbing

The handle pieces of bulk bags are made during this stage. Here, heavier tapes of polypropylene fabric are spun into webbing material. Strips of this material are then cut to precise measurements, which are determined by the size of the bags in production. These strips form the handles, or lifting loops, of each bag. On most bulk bags, the webbing strip lines the seams along each of the four sides, with handle loops above each end.

Sewing

At this stage, the various pieces that comprise the bulk bag including both the square and rectangular pieces of polypropylene fabric, as well as the heavier lifting-loop strips are put together with an industrial sewing machine. Bulk bags are sewn together in mass quantities by a team of trained hands under the watchful eye of technical supervisors. Each seam must be straight, tight and secure, with no creases or bends along any of the sides or bottom ends.

Inspection and Packing

Once a line of bulk bags has been sewn together, each bag is inspected by quality control inspectors. The purpose is to ensure each bag meets the required standards of strength and durability for a product line of bulk bags.

Qualified bags are compressed and grouped into select numbers for distribution by using a bale press, the results of which allow for the neat and easy packing of the bags.

PP Multifilament Yarn / Thread

A process and apparatus for producing multi filament yarn from polypropylene polymer. The process includes the steps of spinning an undrawn yarn using a spinnerette, and winding the undrawn yarn on a bobbin. Subsequently the undrawn yarn is unwound so that no twist is imparted to the yarn and the yarn is then drawn between godet rollers through a convention oven, the drawn yarn being wound on a bobbin.

Twisting

The twist binds the fibres together and also contributes to the strength of the yarn. The amount of twist inserted in a yarn defines the appearance and the strength of the yarn. Twisted yarn will move in to packing for distribution