The Bulk Bag Manufacturing Process
How our bulk bags make the grade
Not all bags are created equal.
With our FIBC (Flexible Intermediate Bulk Container) bags it’s definitely a case of ‘more than meets the eye’.
Hardworking bags like these need to meet rigorous safety standards, to ensure they are up to the job.
Making them is a fascinating process that starts with just a few small polymer granules.
Sound interesting? Let us take you on a quick journey of the production process.
1. Extruding the tape lines/thread
Like any woven fabric, the process starts with creating the thread. But rather than being spun like wool or cotton, our process starts with melting plastic. Polypropylene (PP) resin and other additives are fed into an extruder to produce PP tapes of varying thicknesses and widths. The melted resin forms PP sheets that are stretched by rollers, then slit into each tape end and wound onto a bobbin.
2. Weaving the fabric
These giant bobbins are then loaded onto stands and the tape is woven into FIBC fabric on special looms, to make either circular shaped bags or U-panels, for the various FIBC bag styles.
3. Coating for purpose
For bags that need to be moisture and sift-resistant, the fabric is vacuumed to release dust particles and passed through a static eliminator. It then goes through a lamination process, where a protective coating of polypropylene and other additives is applied. Breathable bags are not coated.
4. Made to measure
This is where it gets a little sci-fi. A computer program controls precision cutting, slicing the woven fabric from the rolls into the sizes required for the bag assembly process.
Bulk bags present a great opportunity for branding. Custom printing takes place before the bags are sewn up, using an approved printing ink that dries quickly to eliminate smears and running.
5. The human touch
And, because computers can’t do everything, our highly-trained staff complete the manufacturing process by sewing the fabric together to create each bulk bag. If requested, bags can be sewn in a clean, FDA approved room to maintain sanitation requirements.
6. Quality control
By following a strict quality control system throughout the manufacturing process, we produce FIBC bags that are both fit for purpose and safe to use.
You can be assured that our bags meet the required specification and safety workloads, protecting both their contents and the people handling them.