Flexible intermediate bulk containers (FIBC), also known as bulk bags, are large, industrial, flexible containers that are designed for the transportation and storage of dry bulk goods, including flowable products such as sand, grain, fertiliser, chemicals, and more. These bulk bags go through a particular manufacturing process which ensures their quality and longevity.
The first stage of manufacturing an FIBC is to acquire the raw material, which is polypropylene.
Once this raw material is acquired, it is put through the extrusion process, which is the process of heating and then extruding the plastic polymer into the required strands or tapes, which have a specific shape and width. During this process, the tapes are checked to ensure they have the proper tensile strength.
Once the extrusion is completed, the resulting plastic tapes are then put through the weaving process. Weaving is where the tapes are placed on looms and then interwoven to produce a fabric made from the plastic extruded types.
Once this polypropylene fabric is woven into a fabric and is strong enough to carry goods, it is then checked and proved to ensure that it has the appropriate appearance and quality of strength.
Depending on the type of bulk bag being manufactured, the next step could include moisture-proofing. Since it is a woven product, there are tiny holes that allow moisture to get through, which means that moisture-proofing is sometimes required. This is a special coating that is applied to the bulk bag and helps it remain moisture free.
In other cases, FIBCs simply have liners inserted into them later on, which also act as a moisture-proofing material.
Cut To Shape
After all this, the fabric that results from the weaving is cut into the appropriate length and width according to exact measurements needed for the fabrication of bulk bags. Different bulk bags might have slightly different shapes. It is at this stage that these shapes are cut.
In many cases, bulk bags require printing. In other cases, companies would like their logos or other information printed on the bags, which is also done before the bags are assembled. At Tufbag, we can print up to four colour print options and print on all four sides of the bag.
Once the bags have been cut to shape, they are sewn together. At this stage, the handles are also sewn on through a special stitching process, and the bags are finally put together in full.
After the FIBCs have been manufactured to completion, they require inspection by a qualified quality control specialist. It is important to ensure that the bags meet certain requirements, as they will be handling customers’ goods and cannot afford to fail.
They’re also load-tested to ensure they can carry the advertised load without any issues. The strength of the bags must be ensured before they are delivered to the client.
Packing And Dispatching
Once this is achieved, the final step is to pack the bags and dispatch them to the clients for use. This rigorous production process is carefully monitored, and we ensure that we can trace any production errors back to the problem’s source ‒ even if that problem is the raw material itself ‒ to ensure that quality is always met.