FIBC bags are created from polypropylene woven
fabrics using different procedures and the expertise of technicians. The PP
fabric is also stabilised against UV detorsion. Virgin polypropylene Fabrics
are a very versatile material (which is based on petroleum) and are used
largely in bulk bag manufacturing.
We have listed below the steps which are
involved in the making of a Bulk Bag.
Extrusion & Winding
The first step of manufacturing the bags
implicates extrusion, where a mix of pure ingredients viz. polypropylene
granules, UV MasterBatch, calcium carbonate, and the tint is melted and shaped
into tapes in an Extrusion plant. During this procedure, the tensile stability
of the tapes is verified. The tapes are reeled on bobbins which are kept and
later loaded onto looms for weaving purposes.
Weaving
The bobbins of tapes from the excursion plant
in the above stage are loaded onto weaving looms which can be Circular Looms,
or Flat Sulzer looms depending on the user's requirements. In this process, the
fabric utilised in the manufacturing of Bulk bags is formed. The same material
of bags is also used to manufacture duffle, bottom, and top spouts.
Lamination / Coating — Optional
Depending on the needs of the customer, the
woven weaved fabric may be coated with a semi-clear PP film that is connected
to the woven material to develop a moisture fence.
Uncoated / Unlaminated
The polypropylene fabric material is
breathable and not ideal for commodities like sugar and salt which should never
be disclosed to water, including water that gets sucked from the vapor in the
air.
Coated or Laminated bulk bags are comfortable
for the transportation of light powdery products, like flour, that could
otherwise shift through uncoated bags when moved or shaken.
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Cutting
The PP woven fabric in the form of risk is
grazed into an automatic cutting machine which cuts into different panels of a
particular size.
The automatic procedure guarantees the
uniformity in size of the cut panels. These panels are now prepared for
stitching or printing Purposes.
Printing
Once the fabric cut panels arrive after
cutting, now it's time for printing. So, they are put into the printing
machine, and the logo/artwork imprint is made over the material. It is this
tactic that the trademark name or symbol of the customer is printed on the bag.
The artwork/logo up to colorslours can easily be re-print.
Webbing
The loops of the bags used to raise the kits
are prepared at this stage. The additional tapes of polypropylene are weaved
together on needle looms to give them the form of webbings. This webbing is cut
into a particular size and stitched to the bag to take the shape of the lifting
loops of the bags. The color of the tape is white as standard, but can also be
created in any different color like Red, Blue, Green, Yellow, etc. It depends
on your customer's requirements.
Sewing
All the elements like material cut panels,
webbings, handouts, and duffle are brought jointly and stitched by expert
tailors to give form to every bulk bag. The bags are examined by skilled
supervisors to assure that it is free from any errors.
Inspection
Technically qualified experts have to do the quality
checking of the bags. Every bag is thoroughly verified and made sure that it is
safe to use.
Cyclic Top Lift Test
Some randomly chosen bags are also picked up
from the production unit and are subjected to lifting on the test ring. It
assures that the safe working load criteria of the bag are fulfilled.
Packing / Palletizing
After inspection, the bags are folded and
placed inside a bale press machine and packed on a pal which is ready to be
stored in a container for transportation.
The Cyclic Top lift test needs the filled bag
hung from its lift loops on a test ring or other lifting tools as weight is
added from the top. If any of the body fabric or lift loops of the bags are
harmed in these procedures, the bag is deemed to fail the test.
The cyclic top lift requires the bags to go
through 70 cycles @ 4X SWL (Safe Working Load) with a final cycle @ 6x SWL for
last approval. For example, a 1000 KG, 6:1 bag will be used for 70 cycles of
load @ 4 X 1000 KG, and in the 71st cycle, the pressure will be boosted
continuously until the bag is ruptured or damaged.
Compression Test
In the compression test, a total load of 4
times the SWL of the bag is kept on top of the bag for 6 hours. If this load
causes any harm to the bag, then the test is considered as failed, and also
bags are supposed to be not relevant for users.
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FIBC Drop Test
The Bulk Bag is stuffed with a material
similar to one being filled in reality up to 95% of the SWL of the bag. The
filled bag is put down from a height of
2.6 feet or 3.9 feet depending upon the classification of the bag on a
rigid surface. After that, the bag should not lose out any material.
Tear Test
In the tear test procedure, a 10 cm knife cut
is given to the bag at an angle of 45 degrees. The bag is stuffed to twice the
capability of the bag and then raised and held in place for five minutes.
For the test to be passed, the cut size should
not be larger than 2.5 cm.
UltraViolet Radiation
The Bulk Bags are fabricated with Woven Polypropylene fabric and are very strong. However, over an extended time, the UV radiation of the sun can weaken the structure of the bag.
It should be
remembered that bulk bags can raise up to 2000 KG of material. Polypropylene is
a very dependable material, but you should evade anything that could
potentially weaken a material expected to bear over a thousand kilos of weight.
Conclusion
After reading the article we get to know the
complete information about the manufacturing process of bulk bags. SinghalIndustries is the leading bulk bag manufacturer in the country.
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