How to Choose the Right Jumbo Bag|FIBC|Bulk Bag for Your Needs

Jumbo Bags (FIBC) are the ideal choice for transporting and storing heavy goods. However, selecting the right Bulk Bag for your needs requires considering some important factors:

  1. Safe Working Load (SWL): Determine the load capacity the bag needs to withstand. Bulk Bags typically have a safety factor of 5:1 or 6:1, suitable for heavy-duty transport.
  2. Material and Design: Choose high-quality polypropylene material and consider designs like U-Panel, Circular, or Baffle to ensure durability and strength.
  3. Top and Bottom Types: Consider the type of top (duffle, spout top) and bottom (flat bottom, discharge spout) that fit your filling and discharging processes.
  4. Special Features: Look for additional features such as anti-static (Type C, D), UV resistance, or moisture resistance depending on storage and transport conditions.
  5. Safety Standards and Certifications: Ensure that the Jumbo Bag is manufactured according to international safety standards like UN, ISO to protect the goods and ensure user safety.

Choosing the right FIBC Bulk Bag tailored to your specific needs will optimize efficiency, safety, and cost-effectiveness in your logistics and storage operations.

Why FIBC is the Optimal Choice for Heavy Cargo Transportation?

Flexible Intermediate Bulk Containers (FIBC), also known as Bulk Bags, are increasingly becoming the preferred choice for transporting heavy cargo across various industries. Their design and material offer numerous advantages that make them ideal for handling large quantities of heavy materials safely and efficiently.

1. High Load Capacity: FIBC bags are designed to carry loads ranging from 500 kg to 2,000 kg, making them perfect for transporting heavy cargo such as grains, chemicals, minerals, and construction materials. The robust polypropylene fabric ensures the bags can handle substantial weight without tearing or bursting.

2. Safety and Durability: With safety factors of 5:1 or 6:1, FIBC bags are tested to withstand stress and extreme conditions. They are built to be UV resistant and can endure harsh weather, making them a reliable choice for outdoor storage and transportation.

3. Cost-Effective: FIBC bags offer a cost-effective solution due to their reusable nature. Unlike traditional packaging methods, Bulk Bags minimize the need for secondary packaging and pallets, reducing overall shipping costs and maximizing storage space.

4. Easy Handling and Versatility: Equipped with lifting loops, FIBC bags are easy to handle with forklifts or cranes, streamlining the loading and unloading process. Their versatility allows them to be used across different industries, from agriculture to pharmaceuticals.

5. Environmental Benefits: FIBC bags are eco-friendly as they can be reused multiple times and are recyclable. Their efficient design helps reduce waste and supports sustainable business practices.

Choosing FIBC for heavy cargo transportation ensures safety, cost efficiency, and environmental sustainability, making them the optimal choice for modern businesses.

What is the Safety Factor of the Lifting Straps on Jumbo Bags?

The safety factor of the lifting straps on jumbo bags, also known as FIBC (Flexible Intermediate Bulk Containers), is a crucial parameter that ensures the safe handling and transportation of bulk materials. This safety factor is a ratio that indicates the maximum load a lifting strap can safely support compared to the working load limit (WLL).

Typically, the safety factor for lifting straps on jumbo bags is denoted as 5:1 or 6:1. Here’s what these ratios mean:

  1. 5:1 Safety Factor: This means that the lifting strap can withstand a load that is five times greater than its working load limit. For example, if a jumbo bag is rated for a working load of 1,000 kg, the lifting straps can handle up to 5,000 kg before they are at risk of failure.
  2. 6:1 Safety Factor: In this case, the lifting strap can endure a load six times greater than its working load limit. For a jumbo bag with a working load limit of 1,000 kg, the lifting straps would be able to support up to 6,000 kg safely.

The importance of this safety factor cannot be overstated. It ensures that the straps can handle unexpected stresses and strains during lifting, handling, and transportation, thereby preventing accidents and ensuring the safety of workers and the integrity of the materials being transported.

Key Points to Consider:

  1. Material Quality: The straps must be made from high-quality materials that can withstand wear and tear, environmental conditions, and the weight of the contents.
  2. Regular Inspections: Regularly inspecting the lifting straps for any signs of damage or wear is essential. This helps in identifying potential issues before they lead to failures.
  3. Proper Use: Ensure that the straps are used according to the manufacturer’s guidelines. Overloading or improper handling can reduce the safety factor and increase the risk of accidents.
  4. Compliance with Standards: It’s crucial to use jumbo bags and lifting straps that comply with international safety standards. This guarantees that the safety factor has been tested and verified under stringent conditions.

In conclusion, understanding and adhering to the safety factor of the lifting straps on jumbo bags is vital for safe and efficient operations. By ensuring that these factors are met, businesses can prevent accidents, protect their workforce, and maintain the integrity of their transported goods.

Optimizing Bulk Bag Handling

Unloading bulk bags can be challenging and time-consuming, presenting significant obstacles for industries dependent on efficient bulk bag handling.

Without the appropriate machinery designed to handle super sacks, manual unloading becomes labor-intensive, error-prone, and potentially hazardous.

By employing proper techniques and investing in bulk bag handling equipment, businesses can overcome the challenges of super sack unloading, enhance operational efficiency, and minimize potential risks. Images in this article are courtesy of Palamatic Process, a leader in bulk material and powder handling.

Let’s start with some general guidance and tips…

Bulk Bag Handling General Tips & Advice

Bulk Bag Unloading

Bulk Bag Unloading

Image credit: Palamatic Process

  • Safety first: Always prioritize safety when handling super sacks by ensuring personnel are adequately trained and equipped with appropriate PPE.
  • Pre-handling inspection: Inspect super sacks for damage, tears, or defects. Check for proper labeling and ensure the bag is suitable for the material.
  • Load capacity: Adhere strictly to the super sack’s weight capacity. Overloading can lead to bag failure and accidents.
  • Secure attachment: Ensure the super sack is securely attached to handling equipment, such as lifters or hooks, before lifting or moving it. Follow the manufacturer’s guidelines to prevent bag slippage or instability.
  • Avoid bag damage: Avoid dragging or sliding the bag on rough surfaces or sharp edges that could cause tears or punctures.
  • Proper storage: Store super sacks in a clean, dry area away from direct sunlight, extreme temperatures, or moisture. Protect the bags from pests to maintain their integrity.
  • Training and communication: Promote effective communication among employees involved in super sack handling. Encourage prompt reporting of issues. Regular training can improve handling techniques and safety awareness.
  • Environmental considerations: Dispose of used or damaged super sacks responsibly, following local regulations. Consider recycling or reusing the bags to minimize waste.
  • Regular maintenance: Keep handling equipment in good working condition with regular inspections and preventive maintenance. Address issues promptly for safe and efficient operations.

Bulk Bag Unloading & Loading Tips

For efficient and safe unloading and loading of super sacks, consider the following tips:

Bulk Bag Unloading Tips

Bulk Bag Unloading Tips

Image credit: Palamatic Process

  • Bag inspection: Always inspect super sacks for damages or defects before unloading or loading to prevent spills or accidents.
  • Appropriate equipment: Use suitable equipment for the weight and type of material in the super sacks. Automated machinery, such as forklifts or cranes, can save time and reduce injury risk.
  • Get organized: Ensure a clear and organized workspace to prevent obstacles or tripping hazards. Clear routes for equipment movement.
  • Apply correct techniques: Follow proper manual handling guidelines to avoid strain or injuries, even when using handling and loading equipment.
  • Communication: Establish clear signals and instructions among the team to ensure coordinated unloading and loading processes.

Bulk Bag Handling Equipment Options

Handling bulk bags can be challenging without the right equipment. Here are some top bulk bag handling equipment options:

Bulk Bag Unloaders

Designed for precision, bulk bag unloaders handle multiple super sacks and large quantities of bulk materials seamlessly. They feature robust construction and can withstand heavy-duty applications and high-density materials.

 

Bulk Bag Lifting Device

A bulk bag lifting device simplifies the process of handling and unloading bulk bags, offering a convenient and safe solution. It features advanced safety points, sturdy construction, and adaptability for various super sack sizes, enhancing productivity and safety.

Bulk Bag Discharger/Dispenser

This equipment facilitates efficient and controlled unloading of bulk bags into downstream processes or storage containers. It includes adjustable retention devices, spout interfaces, and flow control mechanisms, ensuring accurate material flow and preventing spills.

Bulk Bag Hopper

A bulk bag hopper securely receives and stores the contents of super sacks, preventing material bridging or clogging with integrated agitators and flow promotion devices.

Bulk Bag Stand

A bulk bag stand supports and elevates bulk bags during storage or handling, preventing damage from moisture or pests. It ensures safe and efficient handling with a stable base and protective coatings.

Key Takeaways on Bulk Bag Handling Equipment

Super sack handling equipment minimizes manual effort and enhances safety, accommodating various sack sizes and weights. Investing in this equipment improves efficiency, productivity, and operational safety, making it a valuable asset for businesses dealing with bulk materials.

For bulk bag handling solutions, consider FIBC Vietnam – Jumbo Bag VN. Contact us today to discuss your needs.

Sharp Sand has a high percentage of large particles, giving it a gritty texture that is ideal for use as part of a sub-base for paving, especially on top of Type 1 MOT.

Sharp Sand has a high percentage of large particles, giving it a gritty texture that is ideal for use as part of a sub-base for paving, especially on top of Type 1 MOT.

As a free-draining material, Sharp Sand allows proper drainage, reducing retained surface water on patios, driveways, and pathways.

Use it alongside our Type 1 MOT for a stable sub-base for any paving project.

A Sharp Sand bulk bag covers approximately 8.5m² at a standard depth of 50mm.

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.

Rising Demand for Food Grade FIBC Bulk Bags: Implications for Sales and Market Expansion

The FIBC market is forecast to expand at 5.4% CAGR over the estimated period, as per FMI’s analysis. The industry’s size is predicted to reach a market value of US$ 7.5 billion in 2023.

The demand for food grade FIBC bulk bags is on the rise, notably impacting sales as these bags are increasingly sought after by food companies. Traditionally utilized in the chemical industry, FIBCs are now gaining traction in the food sector due to their suitability for commercial food operations.

Key attributes driving this surge in demand include their high load-carrying capacity, versatility, reusability, cost-effectiveness, and eco-friendly materials. FIBCs offer optimal protection for food products through features such as dust-proof seams and laminated fabric sides, guarding against moisture and maintaining product integrity.

Innovative bulk bags incorporating polyethylene, foil, and other lining materials are gaining popularity for their ability to shield food items from harsh environments, spillage, and damage. Furthermore, the ease of customization and quality printing options enable end users to establish their brands effectively and promote products with confidence.

Top Highlights from the FMI’s Analysis of the FIBC Market: 

  • The Europe region acquired a massive share of 32.4% in the FIBC industry in 2022. Regional growth is expected to continue exhibiting an upward trajectory in the coming years.
  • In the overall FIBC industry, North America gained a 24.9% market share in 2022.
  • The United States FIBC industry is forecast to garner more than 18.9% value share in the year 2023.
  • The German market is expected to procure a value share surpassing 5.6%% in 2023.
  • The Japanese FIBC industry is projected to obtain a value share exceeding 8.1% in 2023.
  • The India FIBC industry is forecast to expand at a CAGR of 6.9% over the forecast period.
  • The Chinese FIBC industry is projected to accelerate at a CAGR of 5.7% over the estimated period.
  • The United Kingdom is anticipated to expand at a CAGR of 3.1% from 2023 to 2033.
  • Based on capacity, the ‘above 750 kgs’ segments gained 55.5% market share in 2022.
  • Based on end-use, chemicals, and fertilizers acquired a 41.1% value share in 2022.

Innovation Watch: Key Developments in the Market

  • In May 2023, Packem Umasree commissioned a sustainable FIBC plant in Ahmedabad. This is the company’s first plant in India and is second to the one built in Brazil. The company manufactures 100% sustainable FIBCs or jumbo bags made of recycled PET. The Brazil unit of the company serves the local market, whereas the new plant in India is projected to cater to markets outside of Brazil. The company is expected to export a substantial proportion of the Ahmedabad plant’s output to Europe and North America.
  • Global-Pak announced a new recycling program in September 2022. The corporation is working with PureCycle to process and recycle bulk bags. PureCycle deploys a solvent-based purification technology to process polypropylene waste into an extremely pure resin that can be constantly reused and recycled. One of the many products the company is interested in is used bulk bags.

Global FIBC Industry by Category

By Packaging Type:

  • Q-bags
  • Baffle Bags
  • Circular Bags
  • 6-panel
  • Others

By Capacity:

  • Upto 250 Kg
  • 250 kgs – 750 Kgs
  • Above 750 Kgs

By End User:

  • Building & Construction
  • Chemicals & Fertilizers
  • Food Products & Agriculture
  • Pharmaceuticals Products
  • Mining

By Region:

  • North America
  • Latin America
  • Europe
  • Middle East and Africa
  • East Asia
  • South Asia
  • Oceania

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.