Companies are continuously looking for ways to maximize profit throughout the industrial sector while reducing expenses and preserving space. There, FIBC bags/ Bulk bags have contributed to this goal by hundreds of companies worldwide. However, when considering the FIBC Manufacturing process, it seems to be complicated, and it is worth having a deep look.

At this time, bulk bags provide an efficient and economical solution to package items, storage, and transport, from the food and pharmaceutical industry to manufacturers of gardening products and building equipment. They are stored in safe, safe, and sanitary containers before a product line leaves the manufacturing plant. Moreover, the container must have the capacity to carry weight and protect contents from airborne pollutants and humidity, whether the contents consist of granular mass or larger equipment. The materials of each sack reach the same pure and clean qualities as packaged initially when they are stored and delivered in quality bulk bags.

The effectiveness, durability, and usability of bulk bags obtained from organizations are due to the solid materials utilized in manufacturing these bags. When producing bulk bags at high-quality plants, there is also a high degree of scrutiny involved. Furthermore, the inspection process helps verify that every bag can comply with international safety standards when transporting items, chemicals, medications, and consumables.

FIBC Manufacturing Process Step by Step

When considering the production process for bulk bags, it consists of many phases, irrespective of the design or customer requirements. Of course, every bag must face a cyclical test for SWL compliance and safety factor, regardless of whether it has to be square, tall, overbuilt, or cost-effective.

Laminating treatment is ideal for increasing the moisture barrier for items that require a low moisture transfer rate. However, it is essential to weave and cut the fabric before the bag building begins. The process of manufacturing bulk bags consists of 11 key stages.

Extrusion

The initial stage is extrusion, which melts a mixture of virgin components and forms tapes of specific measures. This procedure utilizes polypropylene (PP) granules, a trace amount of calcium carbonate, UV inhibitors, and maybe color pigments. The assessment of the durability of the tapes is pretty necessary at this point. Then, during the preparation for the weaving step, it is necessary to load the tapes onto industrial bobbins.

Weaving

On weaving looms are loaded the tapes made by PP granules. In this case, the polypropylene fabric that makes up the body is woven into shape for a bulk bag. The material is sufficiently sturdy to convey a wide range of industrial goods and consumables. It is “breathable,” though, and hence vulnerable to moisture transition. The woven PP material is also utilized for loading and unloading components and the material for bulk bags.

Moisture – proofing

By coating the fabric with a special lamination, it is possible to make each bag humidity resistant. But, this totally depends on the customer’s demands. Lamination is the technique that is perfect for the humidity resistance of bulk bags. Moreover, moisture proofing is essential for bulk bags that carry granular items and for any product that should not be exposed to humidity.

The un-laminated material of polypropylene comprises small strands with microscopic pores in each fabric. The material is essentially breathable. The transport and storage of diverse materials can be acceptable quality, however not suitable for selected products. For example, sugar and salt, including water absorbed in the air, should never be exposed to water.

However, laminated bulk bags help transport light powdered materials such as flour that would normally sieve through the weaving gaps of the polypropylene fabric when moved or shaken. The loss could be significant during a large-scale flour transport. Flour is kept contained in laminate-coated bulk bags until it reaches its destination.

Cutting

Firstly, the polypropylene fabric is placed into a slicing machine and cut into precise shapes. The dimensions are determined by whether the process produces sides, edges, or bottoms. Automatic measuring assures exact lengths for each cut. Whether the bulk bag line is square, tubular, or vertically rectangular, the necessary cuts are made at this phase.

Printing

After cutting the polypropylene fabric into shape, it is passed into a printing machine. Imprints are made on the fabric here. Printing happens at this phase if a corporation wishes to apply the brand name or logo to a line of bags. Depending on the brand, a variety of colors may be used. A heavy-duty printer is required for this method to produce the best impressions possible.

Webbing

This stage involves the production of the bulk bag’s handle sections. Moreover, this procedure consists of twisting thicker polypropylene fabric tapes into webbing material. Then, strips of this material are precisely trimmed to fit the dimensions of the bags being made. These strips serve as the bag’s handles or lifting loops. On most bulk bags, the webbing strip runs around all four sides, with handle loops over each end.

Sewing Unit

A team of experienced individuals sews together massive numbers of bulk bags under the cautious eye of technical supervisors. This unit is responsible for the numerous components of a bulk bag — including the square and rectangular polypropylene fabric pieces, as well as the heavier lifting-loop strips — It is essential to use industrial sewing machines for this process. Every seam must be straight, secure, and free of wrinkles or bends along the sides or bottom ends.

Inspection

After sewing a line of bulk bags together, quality control inspectors scrutinize each bag. The goal is to guarantee that each bag fulfills the requisite strength and durability standards for a bulk bag product line. Any bags found to be inadequately stitched are removed.

Burst Test

A random sample of bulk bags is placed in a testing ring to determine if they pass the Safe Working Load (SWL) test. Typically, it is necessary to undertake this procedure before the general manufacture of bulk bags. Once the production process has been completed, random bags are burst tested to confirm whether the SWL has been reached or not. This procedure assists in ensuring that the bags produced are sturdy enough for their intended use.

Packing

At the end of the mass-manufacturing process of bulk bags, it is time to compress and organizing into specific numbers for bulk distribution. Compression takes place in a bale press, which enables the bags to be packed neatly and efficiently.

Storage

After everything is completed, the bulk bags are baled, packed, and transported to a storage area Distribution of the bulk bags to various customer premises is the next step. Once customers receive the packed bulk bags, they are ready to be opened and used for transportation or storage of building materials, waste, food products, or chemicals.

The Utilities Used in The FIBC Manufacturing Process

• Tape Extrusion Line:
• Compressor: Capacity Pressure-165 CFM, 6-7 bar, Separate air tank of capacity 1,000 liters is recommended for tape line & winders (excluding tape guns)
• Air Drying Unit: Capacity 165 CFM, Pressure 6-7 bar, Dew point 3-degree Centigrade
• Chilled War Requirement: Process Requirement 58 TR, flow rate: 42,686 L/hr, Intel Temp: 18 degree centigrade
• Water pressure: 4 bar
• Filament/Tape Winder: Three-phase voltage with mains supply of 3X 415 V/50 Hz or 3X 415V/50 Hz or
• 3X420V/50 Hz with separate neutral and earth Admissible fluctuations
• Voltage- 10% to +5%
• Frequency : +/- 2%

What are the Machines that Play a Huge Role Throughout The FIBC Manufacturing Process?

BCS machine

This machine is capable of converting plain woven (uncoated or coated) and leno fabric into bags. It is a high-speed conversion line that combines cross-cutting, bottom folding, sewing, and lastly, stacking of finished HDPE/PP woven fabric bags. Additionally, special attachments are available for manufacturing gusseted bags, perforated bags, and bags with an easy-open topstitch.

Features – High working speed, the design that is user-friendly, energy consumption is minimal, low-cost maintenance

BCS-liner machine

The manual method of insertion into the woven bags is automated and replaced. These liner bags are ideal for packaging hygroscopic packagings, such as sugar, salt, chemicals, and minerals.

Features – Dimensional Valve Precision, improved packing efficiency, low usage of energy, low cost of maintenance.

LM-650 machine

It is the world’s first high-speed “Back Seam Sack” manufacturing machine. It is constructed entirely of woven polypropylene tape fabric laminated with reverse BOPP film and utilizing integrated tube and bag manufacturing procedures.

Features – Environmentally friendly and light bags, savings on materials, low manufacturing costs, simple processing, packaging that is both robust and appealing

Woven Sack Gusseting & Cutting Machine

The Gusseting & Cutting Machine for Woven Sacks creates woven sacks of various lengths and diameters. When considering the machine, it has a servo motor that allows you to cut bags and bags precisely. Moreover, the device has a high-quality alloy steel cutter, made according to advanced technological standards, and completes the process with precision and exquisite finish.

Jumbo Bag Fabric Cutting Machine

Bag Cutting Machine for Jumbo Bags plays a huge role in various packing processes. It is backed by cutting-edge technology and the usage of quality-tested elements and machine parts to ensure that they operate optimally in associated operations. On the other hand, these machines can process bags with a width of 400 to 1800 mm and a length of 600 to 9999 mm and produce 22 bags per minute. These are efficient in terms of utilization and have an easy-to-use interface, and require little maintenance.

Features – effective Sturdy appearance, easy to maintain, low-cost maintenance

Liner Insertion Machine

The BCS-liner is an automated solution for cutting/sealing and accurately inserting PE liner into woven bags, integrated into a bag conversion system, for packaging all types of hygroscopic products such as sugar, salt, fertilizer, feed mineral, and chemicals. The machine can stitch liners to the woven fabric’s bottom fold or let the liner loose inside the bag. Precision engineered to meet the unique requirements of each customer.

FIBC Bags manufacturing Companies

ABC Polymer Industries, USA

ABC Polymer Industries has been selling Flexible Intermediate Bulk Containers (bulk bags) to customers throughout North America for over two decades. Whether you are packing dirt, chemicals of pharmaceutical class, or whatever, your bulk bag experts have the know-how and experience to develop and implement the packaging solution that meets your demands best. They assist you in managing changing inventory requirements, optimizing budgets, ensuring just-in-time deliveries.

They maintain a ready-to-ship inventory of over 400,000 bags at the North American distribution centers, with another 100,000–150,000 bags in route each month. Apart from a diverse range of standard goods, they offer the flexibility and competence to create entirely customized FIBC bags with features specific to any purpose.

Industries they serve;

• Food
• Hazardous materials
• Plastics
• Pigments and Coatings
• Building materials
• Recycled products
• Aggregates
• Pharmaceuticals
• Chemicals
• Mineral products
• Agricultural

Alpine FIBC (Pvt) Ltd, India

Alpine FIBC Pvt. Ltd. is a renowned manufacturer and supplier of a wide variety of FIBC (Flexible Intermediate Bulk Containers) bags, including the following:

• Food Grade bags
• Pharma Grade bags
• Baffle bags
• UN Certified bags
• U Panel bags
• 4 Panel bags

In addition, the company operates an international standard clean room, utilizes advanced machinery, and maintains an advanced quality control laboratory staffed by highly experienced and knowledgeable personnel.

Moreover, the organization offers the most outstanding products with the highest quality and customer satisfaction. As a result, the company has developed solid commercial relationships with each of its clients. 

In addition, they provide a variety of sectors as follows:

• Foodgrains
• Sugar
• Cow feed
• Fish Feed
• Pulses
• Spices
• Dates
• Agricultural products
• Chemical and fertilizer
• Resin and polymer
• Rubber
• Minerals
• Cement
• Sand
• Soil, and

Moreover, this company provides recycling services.

Alpine FIBC Private Ltd offers FIBC designs as follows:

• FIBC bags
• Baffle FIBC bags
• UN FIBC bags
• Conductive FIBC bags
• Dissipative FIBC bags
• U Panel FIBC bags
• 4 Panel FIBC bags
• Circular FIBC bags
• Conical FIBC bags
• Ventilated FIBC bags
• Food grade FIBC bags
• Pharma grade FIBC bags
• FIBC liners

BAG Corp., Mexico

BAG Corp, headquartered in Richardson, Texas, is a bulk handling and supply chain solutions provider with a single mission: to assist organizations in managing all of their bulk handling needs from a single source. Furthermore, BAG Corp’s production resources for the Super Sack container and related FIBC products include a North American manufacturing facility in Mexico and international manufacturing and warehousing partners who ensure that all our FIBCs meet BAG Corp’s stringent specification and performance standards.

BAG Corp is first and foremost a trusted advisor to its clients. Certainly, they can assist their clients in meeting clients’ supply chain goals by learning about their unique requirements. Moreover, their consultancy, engineering, technical support, supply chain, and logistics management services widely help to accomplish their clients’ goals. 

On the other hand, BAG Corp ensures the highest quality of your goods. Moreover, they have almost unlimited worldwide manufacturing capacity, they can offer bulk bags in a timely and cost-effective manner. Additionally, they maintain a stock of over 360,000 FIBCs available for rapid delivery.

Asia Bulk Sacks Pvt. Ltd, India

Since its start in 1984, Asia Bulk Sacks Private Limited has been the trusted name and first choice of its clientele. In addition, their extensive history and experience have enabled them to develop and show an excellent list of packaging materials in a wide variety of configurations. Moreover, we can recognize this organization as a 100 percent export-oriented firm with over 35 years in the industry. Of course, they manufacture and ship 3.5 million FIBCs (up to SWL 4000 Kg) annually to customers in 35 countries. When considering their client base, it consists of various industries, including sugar, peanuts, fertilizers, polymers, chemicals, minerals, cement, mining, and animal feed.

Available FIBC designs are as follows:

• U+2 panel | 4+1 panel | Circular FIBCs | Baffle-FIBCs / Q-bag
• One / Two loop FIBCs
• UN certified FIBCs 
• Ventilated FIBCs
• TYPE-B FIBCs (breakdown voltage < 6 kV)
• Conductive FIBCs
• Dissipative FIBCs

Customizations:

• Standard Baffle | Net Baffle | Gambo Liner Baffle | Tie Baffle
• All designs with corner & cross corner loops
• FIBCs with conical top/bottom
• FIBCs with PE liner insertion (Form fit, Tabbing, Glued and Flange)
• Antistatic Liners
• FIBCs with single, double, triple dustproof seams

Berry Global. Inc, USA

Berry develops creative packaging and engineered products that they feel improve both people’s lives and the Planet. They accomplish this every day by combining their outstanding global capabilities, sustainable leadership, and deep knowledge in innovation to serve customers of all sizes worldwide. They manufacture a broad range of Flexible Intermediate Bulk Containers (FIBCs) in various sizes to accommodate both large and small volume requirements. Their bags consist of FDA-approved materials and have a sturdy woven polypropylene design with bespoke features to match the specific needs of each application.

Industries they serve;

• Minerals and Mining
• Agriculture
• Chemicals
• Food production
• Plastics and Resins
• Pharmaceuticals
• Construction Materials and Clean Up
• Landscaping, Sand, and Soils

Materials for FIBC Bags

Virgin polypropylene is the building block for the manufacturing process of FIBC bulk bags. Polypropylene is a petroleum-based polymer. Certain FIBCs also include an inner lining made of low-density polyethylene for added moisture resistance (LDPE). Furthermore, polyethylene contributes to ensuring that no moisture from the air enters through the material and absorbs the contents.

Polypropylene fabric is a generic term that refers to any textile material made from the thermoplastic polymer polypropylene. It is possible to transform polypropylene, or Olefin into a textile that is suitable for upholstery and performance materials. Due to the absence of active dye areas, the material is extremely easy to clean and stain-resistant. Additionally, it is bleach-cleanable and will not fade like other natural textiles and fibers.

Material Suppliers for FIBC bags

Environmental Composites

Manufacturer of elastic, woven, and nonwoven fabrics, needle punched felts, superabsorbents, plastic sheets, carbon fiber products, and flame retardant veils. Regarding, Environmental Composites, we can find these fiber types: natural, recycled, synthetic, and carbon-based materials, thermoplastic, polyester, polypropylene, nylon, and PTFE. Moreover, the company offers secondary services like heat-setting, surface singeing, slitting, sheeting, calendaring, and kitting. Of course, these are ideal for industrial fabric, filtration, absorbent, insulation applications, and specialty and consumer products.

Owasco Industries

Owasco Industries is a packaging solutions manufacturer. Textile wiping cloths, paper towels, lint-free/low-lint wipers, dusting wands, dry mops, scrubbing mop pads, bags, aprons, films, liners, and ties are just some of the products available. Furthermore, folding, stitching, printing, perforating, slitting, rewinding, bottom and side gusseting, laminating, cutting, elasticizing, and sonic and heat sealing are just a few of the capabilities. They serve a few industries such as oil, gas, mining, drilling, automobile, aviation, medicine, education, flooring, and hair salons.

Tex Tech Industries

This company manufactures fabrics, textiles, designed and fabricated components, OEM parts, and oil webs. They use polymers, composites, and fibers mainly as materials. Additionally, coating services are available for knits, wovens, nonwovens, and films. Suitable for aircraft and aerospace, seats, tennis balls, civilian, and military purposes.

Hanwha International LLC, USA

Hanwa International manufactures specialty chemicals, additives, resins, compounds, and composites. Plastic, paint, coating, adhesive, chemical, rubber, polyurethane, asphalt, and epoxy are all examples of additives. 

They offer a variety of resins as follows:

• High Impact Polystyrene (HIPS)
• Polystyrene (PS)
• High-Density Polyethylene (HDPE)
• ABS
• Acrylic
• LDPE (5320 & 955)
• Polycarbonate
• Polyethylene (PE)
• Polypropylene (PP)
• PETG
• Polystyrene (PS)
• PVC
• Polyethylene terephthalate (PET)
• Nylon
• Polyurethane
• Polyamide-imide (PAI)
• Polyether.

There are also colorless and translucent 2-ethyl hexanol (2-EH) alcohol sheets available, as well as ethylene-vinyl acetate (EVA) or low-density polyethylene (LLDPE) sheets.

The chemical, construction, aerospace, defense, mechatronics, and solar energy industries all benefit from the company’s services.

GAR Plastics, USA

GAR Plastics is a manufacturer of raw materials made from recycled plastic. The following materials are available: ABS, high impact polystyrene (HIPS), high molecular weight polyethylene (HMWPE), PVC, PET, polypropylene, acrylic, polycarbonate, HDPE or LDPE, and nylon. Pellets and extrusion or injection grades are available. Additionally, recycling, repurposing, and toll processing services are available. FDA-cleared.

New Process Fibre Company, Inc., USA

New Process Fibre Company is an organization with ISO 9001:2015 certifications. They manufacture custom extruded polypropylene (PP) sheets and rolls in trimmed widths of 32, 35, and 36 inches, and thicknesses ranging from 0.010 to 0.250 inches are available. 

Natural, white, and black are the standard hues. On request, custom colors are available.

Sustainability and FIBCs: Protecting Our Planet Against Waste

When evaluating corporate waste management and recycling programs, there are a few other issues and considerations that require our attention. At first glance, some waste is noticeable. 

Of course, you can replenish your container cost with expensive plastic containers or cardboard boxes stored in stacks.But, the same heaps have costs of recycling that can slow down. If you want numerous recycling pick-ups each week, or if you run out of space to maintain everything, the prices will continue to grow. So, using FIBC bags with easy solutions can handle most of your environmentally friendly manufacturing problems.

If your company has not optimized the recycling and reuse supply chain, it might become costly. That is why you need to demonstrate that your recycled materials are structurally integral or better than before. When you use recycled materials for totally different uses, they still have to match the new criteria. 

Recycling and reuse are, for many businesses, a way to appease environmentalists. The production and usage of generic blocks, beads, struts, and other materials are less costly than purchasing an industrial recycling service providing premium materials at unaffordable prices.

Sustainability is critical, and extending the Planet’s resources while being lucrative should be a long-term objective!

It is not just about broadening beyond ten or twenty years or even gaining territory. Sustainability research is essential for pure industrialism, pure environmentally friendly design, and everything in between due to changes in legislation, public opinion, unanticipated chain reactions from the environment, and other unknowns. 

Of course, FIBCs are re-usable and easily recyclable!

But, for most industries, the primary recycling problem is locating a suitable recycling site, managing a manageable garbage pile, and delivering recyclable items.

Due to the small weight and convenience with which FIBCs may be flattened, storage is comparable to–or superior to–cardboard boxes and other flat paper goods. Naturally, the exceptional strength and durability of FIBCs make them an ideal solution to transporting hundreds or thousands of pounds in a fragile or broken cardboard box. 

Of course, this is where FIBCs genuinely shine in terms of environmental impact. They combine the recycling center convenience of cardboard boxes with the strength of much larger cargo containers. Comparing FIBCs to more robust containers such as steel sea-worthy containers demonstrates a different point, as FIBCs are far lighter and easier to store than metal containers.

Polypropylene fabric bags are an excellent choice due to their high recycling rate!

FIBCs offer a high reusability rating!

It means that there is no need of discarding the bags under correct handling rules after one or two usages. However, as we all know, polypropylene has the potential of going ahead with the recycling process again and again. Hence there is no need to look for special recycling centers worldwide or within the area at the end of the lifespan of FIBCs. 

Again, weight is a consideration. Of course, using less energy to carry recyclable bags means that your company’s carbon footprint is reduced even when business partners and third-party contractors who manage your recycling are included.