With increasing competition and frequent changes in consumer behavior, companies across all industrial sectors are constantly seeking ways to maximize profits. Bulk bags have made this goal achievable for more than thousands of businesses across the globe. Right from food as well as pharma industries to the manufacturers of construction equipment and gardening products, bulk bags have been providing the most efficacious way to store, transport, and pack products.
Bulk bags are also known as FIBC Jumbo bags and offer high durability along with ease of use. It is possible due to the excellent material used in their construction. However, if manufactured at a well-equipped plant, these Jumbo Bags undergo stringent inspection levels that ensure every bag is meeting international safety standards for the transportation of chemicals, products, and consumable goods.
Coming to the manufacturing of these bulk bags, the process is broken down into following major steps:
1.Extrusion
In this process, a mix of virgin polypropylene, ultraviolet inhibitor, a small amount of calcium carbonate & sometimes color pigment are melted together to convert them into tapes in an extrusion plant. At the end of this procedure, the tapes are wound on bobbins of a particular size and denier. Then tested for their tensile strength. (Reframe).
Extrusion is the first stage of the manufacturing of FIBC Jumbo bags that helps determine the tensile strength of the tape.
2.Weaving
The extruded tape bobbins are loaded in circular/flat weaving looms. Here the tapes will be woven into the fabric of a required specification. At the end of this process, the fabric will be rolled. This fabric will not only be made for the body of the FIBC, but also for the components like fill and discharge spouts.
3.Laminating
Lamination is a step in which polypropylene fabric gets laminated with PP film that fills the microscopic gaps within each weave to create a moisture barrier.
However, it is an optional process and can be carried out as per the customer’s requirement.
4.Cutting
It is an automatic process that is majorly used to get better accuracy in the cut size. Here, the woven polypropylene fabric in rolls will be inserted into the automatic cutting machine. Then, the fabric will be cut into a bit of the desired size.
5.Printing
The body fabric panels are then inserted into the printing machine. A wide assortment of colors can be implemented in this printing process as per customer requirements.
However, a heavy-duty printer becomes essential to deliver the best possible impressions on fabric.
6.Webbing
During this process, the handle pieces of bulk bags are made. Webbing is a process in which heavier tapes of polypropylene fabric are spun into the webbing material accurately while the strips of this material are then cut to the required measurement.
In short, the tapes once woven into the webbing, form the lifting loop of the jumbo bags.
7.Sewing unit
In this process, all of the components used to manufacture FIBC Jumbo bags are gathered together along with the printed fabric. These parts are precisely assembled to the bulk bags by highly skilled personnel.
The process is carried out under the supervision of technically experienced supervisors.
8.Inspection
It is one of the crucial processes in which every bag that is manufactured will be thoroughly inspected by a technically experienced person. This ensures that every bag delivered from the manufacturer is of good quality.
And if faults are found, the bags will be sent for manufacturing again or get rejected.
9.Burst Test
This involves random testing of finished products in the testing rig. This process ensures the Safe Working Load of these bags and is usually conducted with the production sample bag before the commencement of production.
After the production of these Jumbo bags, these random bags from the lot undergo burst tests to ensure the Safe Working Load.
10.Bailing Or Packing
In this process, the jumbo bags that have been produced will be compressed with a bale press and will be precisely packed as per customer requirements.
11.Storage
After these bags are baled, they are immediately moved to a clean storage room where they are kept ready for dispatch.
