Part 2: Cutting, Component Manufacturing, and Sewing

Are you curious about how bulk bags are made and how they’re strong enough to hold thousands of pounds of material? In Part 1, we reviewed how our bulk bag fabrics are produced through extrusion, weaving, and coating. Now, let’s dive into the second phase of production, which includes fabric cutting, component manufacturing, and sewing.

Cutting

In the cutting stage, the woven fabric rolls produced during weaving are moved to the cutting floor. Here, the fabric is cut into specific shapes and sizes based on the finished bag’s specifications. These cuts determine the shape of the bag’s body panels, base and top panels, duffle or spout dimensions, and overall bag style. Measurements are programmed automatically to ensure precise and equal cuts according to the specifications.

Component Manufacturing

This stage involves two sub-stages: printing and webbing.

Sub-stage 1: Printing

After the fabric is cut, the printing plan is defined by the planning team. Once print plates are produced, the data is sent to an automatic printing machine. Impressions, company logos, and colors are then applied to the fabric panels before any sewing processes begin.

Sub-stage 2: Webbing

During this stage, various webbing components are produced, including lift loops, perimeter bands, belly bands, and web ties. Polypropylene tapes are woven on flat looms in the warp direction, and multifilament yarn is woven in the weft direction to produce webbing that supports a 6,000 lb break strength. The Quality Team then checks and approves the mechanical properties and appearance of the fabric.

Sewing

Once all the fabrics are cut, components are produced, and the technical team has reviewed the production plan, the materials are brought onto the production floor for sewing. The line plan is set up based on the attachments and components of each bag. Sewing generally follows this sequence: spouts are attached to their appropriate panels, the body panels of the bag (the “box”) are sewn together using a single safety stitch, and finally, the web components and accessories are attached with the finishing stitch. Different operations are carried out at their respective workstations by trained specialists to produce the finished FIBC bag.

HOW BULK BAGS ARE MADE: PART 1

Part 1: Extrusion, Weaving, Coating

Bulk bags are crucial for transportation, but how are they crafted to be so robust? Here’s a breakdown of how FIBC fabrics and bulk bags are made.

What is FIBC fabric? FIBC fabrics, primarily made from polypropylene, are coated with a synthetic film of polypropylene and polyethylene. These fabrics are designed to be strong and versatile, ideal for transporting dry and flowable products.

How is FIBC fabric made? FIBC fabrics are created through the following process:

  1. Extrusion
  2. Weaving
  3. Coating (Lamination)

Extrusion In the extrusion process, raw materials are melted into tapes of specific measurements. The ingredients include polypropylene granules, a small amount of calcium carbonate, a UV stabilizer, and colored pigments if needed. These tapes are then loaded onto bobbins for weaving.

FIBC Fabrics typically consist of:

  • Polypropylene 94.33%
  • Calcium 3.77%
  • UV treatment 2%

Weaving During weaving, the polypropylene tapes from the extrusion process are loaded onto looms. The fabric that forms the bulk bag’s body is woven into shape with warp (vertical tapes) and weft (horizontal tapes) generally at 10-warp x 10-weft tapes per square inch. This fabric has small gaps, making it breathable, which is excellent for some materials but not suitable for others.

Coating (Lamination) For certain applications, the fabric is treated with a laminate coating. In this process, the fabric passes through a thin liquid film of PP & LDPE material, then solidified by chilled rollers. This coating seals the weave’s voids, enhancing the fabric’s physical properties, making it suitable for transporting fine or flowable products and protecting them from moisture.

The lamination material typically consists of:

  • PP 350 FG 75%
  • LD 1070 LA17 25% (No filler used in the lamination process)

After coating, if applicable, the woven fabric is wound onto large spools and stored until it enters the cutting process, marking the start of Phase 2 of production.

FIBC Material: What Are Bulk Bags Made Of?

Bulk bags are made of polypropylene fabric, a strong, durable, and thermoplastic polymer FIBC material that’s resistant to moisture, chemicals, and UV radiation. Coatings provide extra protection, and bags feature woven polypropylene lifting loops for easy handling.

There are a number of bulk bag specs that are designed to meet Department of Transport (DOT) requirements for transport, including the:

  • Thickness of individual threads (denier)
  • Fabric weight (GSM)
  • Strength of the yarn and fabric.

From these engineering specs, each bag is specifically designed to pass a number of stress tests, including drop and jerk forces, that could affect the integrity of each bag during transport.

When purchasing an FIBC, the most important bulk bag spec is the bag capacity (or bag size), which can range from 500 to 4,000 pounds when filled.

Also, the styles and types of FIBC bags should be considered when choosing an FIBC to meet your product storage and transport applications:

  • Type A FIBC: No Electrostatic Protection
  • Type B FIBC: Surface Breakdown Voltage of <6kV
  • Type C FIBC: Electrically Conductive or Groundable
  • Type D FIBC: Static Dissipative

Within these FIBC bag types, you will find different styles to meet your bagging needs, including rectangular or four-panel bags, duffle top bags, and circular bulk bags. For each bag style, the manner in which they are constructed will be similar, other than the type of material, size, and shape.

If you’re unsure which of these bags you need, get in touch with the team here at Palmetto Industries so we can discuss your needs further.

The FIBC Bags Manufacturing Process

The FIBC bags manufacturing process we take is as follows:

  1. Extrusion
  2. Weaving
  3. Vacuuming
  4. Lamination
  5. Printing
  6. Cutting
  7. Sewing
  8. Final Testing

Let’s take a look at each of these steps in more detail so you can see exactly how we optimize your product for your needs:

1. Extrusion: Feeding in the FIBC material

The making of a bulk bag begins with the feeding of polypropylene (PP) resin and other additives into an extruder to produce PP tapes that vary in thickness and width.

The melted resin forms PP sheets that are stretched by rollers, then cut.

2. Weaving

The tapes are then wound onto bobbins to start the weaving process which will create the FIBC fabric.

The fabric weaving is performed on special looms to make either circular shaped bags or U-panels for the various other FIBC bag styles.

3. Vacuuming

If the fabric is to be coated, the bags are vacuumed to release dust particles, and the bag is then passed through a static eliminator.

4. Lamination

A lamination process then applies a protective coating of polypropylene which will increase the bags’ resistance to moisture and sifting. Breathable fabric bags are left uncoated.

5. Printing

At this point, the bags are printed with an FDA-approved printing ink, suitable for food contact. The ink that is used will dry quickly to eliminate smears or running.

6. Cutting

Next, a computer program controls the precision cutting of the woven fabric from the rolls into the required sizes for the bag assembly process.

7. Sewing

Finally, highly-trained employees complete the manufacturing process by sewing the fabric pieces together to create each bulk bag. All bags are sewn in an FDA-approved clean room to maintain sanitation requirements.

8. Final Testing

While we continuously QA our bulk bags through the manufacturing process, at this stage, filler cords are sewn into the seams and the bags will move on through different types of testing to final approval.

Key Takeaways On The FIBC Manufacturing Process

The FIBC manufacturing process involves several key steps, but, depending on the specific requirements, additional processes may be applied.

For instance, coatings like polyethylene or polypropylene can be applied to enhance moisture resistance, and printing machines may add logos or other information onto the fabric’s surface.

After the fabric is woven and any optional coatings or printing are applied, it is ready for bag construction and final inspection. This meticulous manufacturing process ensures that FIBCs meet industry standards and can withstand the rigors of transporting and storing bulk materials effectively.

Types of Jumbo Bags (FIBC) and Their Applications

Jumbo bags, also known as FIBCs (flexible intermediate bulk containers), are extensively used in various industries for storing and transporting dry, flowable materials. These versatile and durable bags come in different types, each with specific properties and applications. This article explores the four main types of jumbo bags based on their static control properties: A, B, C, and D.

Type A Jumbo Bags:

  • Composition: Made from standard polypropylene (PP) or other non-conductive woven fabrics.
  • Static control: No inherent anti-static properties.
  • Applications: Suitable for non-flammable products such as fertilizers, grains, and chemicals.
  • Precautions: Not recommended for flammable products or combustible environments.

Type B Jumbo Bags:

  • Composition: Similar to Type A, but with an added conductive liner.
  • Static control: Dissipates static electricity up to 6000 volts.
  • Applications: Ideal for dry, powdered, and flammable products like flour, sugar, and resins.
  • Precautions: Avoid using near flammable solvents or gases.

Type C Jumbo Bags:

  • Composition: Combination of conductive and non-conductive PP woven fabrics in a grid pattern.
  • Static control: Requires grounding during filling and discharging to prevent static build-up.
  • Applications: Safe for combustible powders and offers protection in environments with flammable solvents or gases.
  • Precautions: Grounding is essential for safe use. Do not use if damaged.

Type D Jumbo Bags:

  • Composition: Constructed with anti-static and dissipative woven fabrics.
  • Static control: Engineered to prevent sparks, dissipate static charges, and eliminate the need for grounding.
  • Applications: Suitable for highly flammable products and offer the highest level of safety in explosive atmospheres.
  • Precautions: Avoid using if the bag surface is contaminated with conductive materials.

Choosing the Right Jumbo Bag:

Selecting the appropriate jumbo bag type is crucial for safe and efficient product handling. Consider the following factors:

  • Product properties: Flammability, conductivity, and particle size.
  • Intended use: Storage, transportation, or specific process requirements.
  • Environmental factors: Presence of flammable solvents or gases.
  • Regulatory compliance: Adhering to industry standards and safety guidelines.

Conclusion:

By understanding the different types of jumbo bags and their specific properties, businesses can choose the most suitable option for their unique requirements, ensuring optimal product protection, safety, and compliance.

The environmental impact of jumbo bags

Jumbo bags, also known as FIBC (flexible intermediate bulk containers), are large bags used to transport and store bulk materials. They are made from a variety of materials, including polypropylene, polyethylene, and woven paper. Jumbo bags are popular because they are strong, durable, and relatively inexpensive. However, they also have a number of environmental impacts.

Jumbo bag vietnam, FIBC Vietnam, #fibc #bigbags #foodindustry #chemicalindustry #constructionindustry #agricultureindustry #miningindustry #logisticsindustry #supplychain #businesssolutions #grainstorage #agribusiness #foodlogistics #agriculture #business

Positive impacts

  • Reduced packaging waste: Jumbo bags can be reused multiple times, which reduces the amount of packaging waste generated.
  • Lightweight: Jumbo bags are lightweight, which reduces the amount of fuel required to transport them.
  • Space-efficient: Jumbo bags can be folded flat when not in use, which saves space.

Negative impacts

  • Non-biodegradable: Jumbo bags are made from non-biodegradable materials, which means they can take hundreds of years to decompose in landfills.
  • Pollution: The production and disposal of jumbo bags can pollute the air and water.
  • Litter: Jumbo bags are often discarded after use, which can contribute to litter problems.

Solutions

  • Reduce: The best way to reduce the environmental impact of jumbo bags is to use fewer of them. This can be done by using alternative packaging methods, such as bulk containers or returnable totes.
  • Reuse: Jumbo bags can be reused multiple times, which reduces the environmental impact. When finished with a jumbo bag, it is important to find a way to reuse it or recycle it.
  • Recycle: Jumbo bags can be recycled into new products, such as plastic lumber or park benches.

Conclusion

Jumbo bags have both positive and negative environmental impacts. By reducing, reusing, and recycling jumbo bags, we can help to minimize their negative impact on the environment.

Jumbo bags: Regulations for production and use

Jumbo bags, also known as FIBCs (Flexible Intermediate Bulk Containers), are widely used in various industries for transporting and storing bulk materials. These bags are made from woven polypropylene or polyethylene and can hold a capacity of up to 2000 kg.

Regulations for the production of jumbo bags:

The production of jumbo bags is regulated by various standards and guidelines set by international organizations such as the ISO (International Organization for Standardization) and the UN (United Nations). These standards ensure that jumbo bags are manufactured with high quality and safety standards.

Some of the key regulations for the production of jumbo bags include:

  • Quality of materials: The materials used for manufacturing jumbo bags must be of high quality and meet the specified standards. The fabric used for the bags must be strong, tear-resistant, and have good UV resistance.
  • Design and construction: Jumbo bags must be designed and constructed to withstand the intended use. The bags must have a safe working load (SWL) that is clearly marked on the bag.
  • Testing and certification: Jumbo bags must be tested and certified by an accredited testing laboratory to ensure that they meet the required standards.

Regulations for the safe use of jumbo bags:

The safe use of jumbo bags is essential to prevent accidents and injuries. There are various regulations and guidelines in place that provide instructions on how to safely use jumbo bags.

Some of the key regulations for the safe use of jumbo bags include:

  • Filling and handling: Jumbo bags must be filled and handled properly to avoid damage. The bags must not be overloaded and must be lifted using appropriate lifting equipment.
  • Storage: Jumbo bags must be stored in a safe and secure manner. The bags must be stored in a dry and well-ventilated area away from sources of heat and ignition.
  • Disposal: Jumbo bags must be disposed of properly after use. The bags must be recycled or incinerated in accordance with local regulations.

Regulations for the environmental protection:

The use of jumbo bags can have an environmental impact. It is important to use jumbo bags in a sustainable manner and to minimize the environmental impact.

Some of the key regulations for the environmental protection include:

  • Use of recycled materials: The use of recycled materials in the production of jumbo bags can help to reduce the environmental impact.
  • Recycling of jumbo bags: Jumbo bags can be recycled after use to reduce the amount of waste going to landfills.
  • Incineration of jumbo bags: Jumbo bags can be incinerated in a controlled manner to recover energy and minimize emissions.

By following these regulations, manufacturers, users, and disposers of jumbo bags can ensure the safety and environmental protection of these important containers.

It’s Time to Find a New FIBC Manufacturer, Look No Further Than Jumbo Bags Vietnam | Khai Anh – A Leading FIBC Manufacturer

It's Time to Find a New FIBC Manufacturer, Look No Further Than Jumbo Bags Vietnam | Khai Anh - A Leading FIBC Manufacturer

In today’s dynamic business landscape, finding the right manufacturer for Flexible Intermediate Bulk Containers (FIBC), commonly known as Jumbo Bags, is crucial for ensuring the efficiency and success of your operations. If you’re in search of a reliable and top-quality FIBC manufacturer, your quest ends here at Jumbo Bags Vietnam | Khai Anh.

It's Time to Find a New FIBC Manufacturer, Look No Further Than Jumbo Bags Vietnam | Khai Anh - A Leading FIBC Manufacturer
#fibc #bigbags #foodindustry #chemicalindustry #constructionindustry #agricultureindustry #miningindustry #logisticsindustry #supplychain #businesssolutions #grainstorage #agribusiness #foodlogistics #agriculture #business

With a reputation for excellence and a commitment to delivering superior products, Jumbo Bags Vietnam | Khai Anh stands out as a leading FIBC manufacturer in the industry. Our state-of-the-art manufacturing facility is equipped with advanced technology and operated by a team of skilled professionals dedicated to producing high-quality FIBC solutions tailored to meet your specific needs.

Why Choose Jumbo Bags Vietnam | Khai Anh?

  1. Exceptional Quality: At Jumbo Bags Vietnam | Khai Anh, quality is our top priority. We adhere to stringent quality control measures at every stage of the manufacturing process to ensure that our FIBC products meet the highest standards of excellence.
  2. Customization Options: We understand that every business has unique requirements when it comes to FIBC solutions. That’s why we offer a wide range of customization options, including size, capacity, design, and printing, to meet your specific needs and preferences.
  3. Competitive Pricing: Despite offering top-quality products and customization options, we strive to keep our prices competitive and affordable. Our goal is to provide value for money and help you optimize your packaging costs without compromising on quality.
  4. Timely Delivery: We understand the importance of timely delivery in today’s fast-paced business environment. With our efficient production processes and streamlined logistics, we ensure prompt delivery of your orders, allowing you to meet your deadlines and commitments.
  5. Excellent Customer Service: At Jumbo Bags Vietnam | Khai Anh, we are committed to providing exceptional customer service and support. Our team of dedicated professionals is always available to address your queries, provide assistance, and ensure your complete satisfaction.

In conclusion, if you’re in need of a reliable and trusted FIBC manufacturer, look no further than Jumbo Bags Vietnam | Khai Anh. With our commitment to quality, customization options, competitive pricing, timely delivery, and excellent customer service, we are your ideal partner for all your FIBC needs. Contact us today to learn more about our products and services, and let us help you find the perfect FIBC solution for your business.

Choosing and Using FIBCs (Flexible Intermediate Bulk Containers)

Flexible intermediate bulk containers (FIBCs), also known as bulk bags or jumbo bags, are a popular and versatile packaging solution for storing and transporting a wide range of materials. FIBCs come in various sizes, materials, and configurations to meet different needs. This article shares some best practices for choosing and using FIBCs effectively.

Choosing the Right FIBC:

  • Consider the product to be stored or transported: Different products require specific FIBC features, such as food-grade certification for food products or anti-static properties for flammable materials.
  • Select the appropriate size: FIBCs come in various sizes, from small 500 kg bags to large 2000 kg bags. Choose the size that best suits your product quantity and handling requirements.
  • Choose the right material: FIBCs are commonly made from polypropylene, but other materials like polyethylene and coated fabrics are also available. Each material offers different properties, such as strength, moisture resistance, and UV protection.
  • Consider additional features: Some FIBCs have features like spout closures, discharge valves, and lifting loops for easier filling, emptying, and handling. Choose the features that best suit your specific needs.

Using FIBCs Safely and Effectively:

  • Follow the manufacturer’s instructions: Always follow the manufacturer’s guidelines for filling, stacking, and transporting FIBCs to ensure safe handling and optimal performance.
  • Properly fill and load FIBCs: Do not overfill FIBCs and ensure they are evenly loaded to prevent damage and maintain stability.
  • Use the right lifting equipment: Use appropriate lifting equipment, such as forklifts or pallet jacks, designed for FIBC handling to avoid accidents and injuries.
  • Store FIBCs properly: Store FIBCs in a dry, cool, and well-ventilated area away from direct sunlight and sources of heat or ignition.
  • Inspect FIBCs regularly: Inspect FIBCs for signs of damage, such as tears, holes, or loose stitching, before each use and discard any damaged bags.

Conclusion:

FIBCs are a reliable and cost-effective packaging solution for various industries when chosen and used correctly. By following the best practices outlined in this article, you can ensure the safe and efficient use of FIBCs for your specific requirements.

Additional tips:

  • Consider working with a reputable FIBC supplier who can provide expert advice and customized solutions based on your specific needs.
  • Keep up-to-date with industry regulations and standards related to FIBC use and safety.

By following these tips, you can maximize the benefits of using FIBCs for your business.

Struggling with Shipping Delays and Rising Costs? Optimize Your Bulk Bags to Maximize Container Space and Slash Loading Times

Bulk Bags, container space, loading time, freight cost, quality bulk bag, packaging partner, food grade standard, NZ food grade standard, quality control, certified packaging process, supply chain

In today’s world of surging international freight prices, every cubic inch of container space counts. Nobody wants to pay for shipping air! Here’s how to get the most out of your bulk bags:

Bulk Bags, container space, loading time, freight cost, quality bulk bag, packaging partner, food grade standard, NZ food grade standard, quality control, certified packaging process, supply chain
Bulk Bags, container space, loading time, freight cost, quality bulk bag, packaging partner, food grade standard, NZ food grade standard, quality control, certified packaging process, supply chain

1. Size Matters: Get the Perfect Fit

  • Choose baffle-constructed bulk bags for maximum stability and optimal space usage during export.
  • Know your container dimensions. A standard 20ft container is 5.89m long x 2.35m wide x 2.39m high.
  • Factor in a slight bulge. Baffle bags expand a bit, so add 20mm to your calculations for each bag’s width and length.
  • Avoid friction damage. Make sure bags don’t rub against each other inside the container.

2. Quality is Key: Invest in Bags That Perform

Not all bulk bags are created equal! High-quality bags mean faster loading and better space efficiency.

  • Partner with a trusted supplier to ensure consistent, top-quality bags that meet your exact needs.
  • Look for:
    • Tight, high-quality weave for optimal stacking and transport.
    • Well-constructed baffles that maintain a square shape with a flat bottom.
    • Sturdy cross-corner loops that make lifting and loading effortless.
    • Food-grade certification if required by your industry.

The Right Packaging Partner Makes All The Difference

In the world of bulk bag export, having a packaging partner who understands the entire process saves you time, money, and headaches.

Let me know if you’d like further refinement or want to rework any other sections!

Bulk Bags: Single-Use vs. Multi-Use – Understanding the Differences

Multi-use-vs.-Single-use-Bulk-Bags-Banner

Bulk bags, or flexible intermediate bulk containers (FIBCs), are indispensable for storing and transporting large quantities of materials. They come in both multi-use and single-use varieties. While both fulfill the same basic purpose, understanding their key differences is crucial for making the right purchase decision.

Multi-use-vs.-Single-use-Bulk-Bags-Banner

Single-Use Bulk Bags

Single-use bulk bags, often called disposable bags, are typically made of polypropylene and designed for one-time use. They effectively store and transport powders, granules, grains, and similar bulk materials. Once used, they are discarded and replaced.

Multi-Use Bulk Bags

In contrast, multi-use bulk bags are constructed from more durable materials like woven polypropylene. They can withstand repeated use, heavier loads, and rougher handling. Multi-use bulk bags are often termed “reusable” due to their extended lifespan.

Key Factors for Choosing Between Single-Use and Multi-Use

Here’s what to consider when making your choice:

  • Cost: While single-use bags are initially cheaper, frequent usage can quickly drive up costs. Multi-use bags have a higher initial price but offer long-term savings due to their reusability.
  • Environmental Impact: Single-use bags significantly contribute to global waste. Multi-use bags offer a more sustainable option, reducing landfill waste and resource consumption.
  • Hygiene: Single-use bags are ideal when hygiene is paramount, such as in the food industry where contamination risks are high. Their disposal after use minimizes cross-contamination potential. Multi-use bags require thorough cleaning and inspections for safe reuse.
  • Storage Space: Single-use bags are space-savers compared to their multi-use counterparts, making them preferable when storage is limited.

Conclusion

Single-use and multi-use bulk bags each have their merits. Single-use bags shine in occasional bulk storage needs and when storage space is at a premium. Multi-use bags offer a sustainable solution for frequent bulk handling of materials. The best choice hinges on carefully evaluating your specific requirements.