Production Process of Polypropylene Woven Bags

Production process of Woven polypropylene bags contains knowledge about plastic industry, textile
weaving, and even chemistry. This part of the document is going to introduce the complete production
process of how the polypropylene resin becomes a finished woven polypropylene sack step by step.

Summarize of Woven polypropylene bags production process.

Overall, though the production process of woven pp sacks requires multiple equipments, it’s still an
industry with simple process flow, easy control of process parameters, easy equipments operation, and
high production efficiency. Actually it’s mostly benefited from its stable and reliable equipments with
safe operation and low maintenance rates. Specific manufacturing process steps of woven
polypropylene (PP) bags will be as follows,

1. Polypropylene tapes drawing.

2. Circular weaving.
3. Coating and lamination.
4. Printing.
5. Cutting and sewing.
6. Baling.

1. Polypropylene tapes drawing.

After raw material of Polypropylene and additives were put into the extruder, it is heated at 190-250 ℃
and sheared by the screw and barrel. After plasticization process, the material is extruded at constant
pressure and velocity. After formed by the tooling die, materials enter into the cooling water in shape of
melted film. After cooling, the film is slit into narrow embryo yarns by the blades. Then the embryo yarn
is being stretched in the oven with high temperature until it comes out in shape of flat tapes. Then the
flat tapes are heat set on the hot rollers, and shrink at low traction speed. Finally, the flat tapes are
rewinded by the disk differential tension winding system. It becomes the base structure of pp woven
fabric and woven polypropylene sacks.

The technological indexes of polypropylene tapes manufacturing are mainly divided into four categories:

1. Physical and chemical modification index. It mainly includes blending modification, blending
ratio, adding ratio of functional additives and blending ratio of recycled materials.
2. Physical property and rheological index. It mainly includes draft ratio, inflation ratio and
retraction ratio.
3. Mechanical performance index. It mainly includes breaking force, relative breaking force, and
elongation at break, linear velocity and linear density deviation;
4. Dimension tolerance index. It mainly includes the thickness and width of flat tapes (yarn).

2. Circular weaving.

First of all, the warp tape is drawn out from the bottom of each row of spindles on the warp frame.
Through the porcelain hole on the warp frame, to the first vertical plate, to the yarn pressing roller, to
the yarn feeding roller, to the yarn guiding roller, to the second vertical plate, to the yarn guiding roller,
to the magnetic hole, to the tension rod, to the round steel buckle, to the warp fixing ring and reach the
reserved cloth base. Meanwhile, the weft tapes are loaded into the shed, when the circular looms starts
to run, shuttles move in circling running. With close cooperation of the warp tape supplying system and
the shuttle pushing device, warp tapes and weft tapes are knnited as tubular woven polypropylene
fabric. Traction device was equiped on the top of the loom which would guides tubular fabric to a press
roller and then goes to rewinding device behind the warp frame.

3. Coating and lamination.

Working principle of coating and lamination are exactly same which is to compound the melted
polypropylene and Polyethylene onto pp woven fabric. The difference is when we saying lamination, we
are using BOPP film or kraft paper to compound with woven polypropylene fabric while doing coating.
Coating and lamination could be made on one side or both sides of woven pp fabric. For different
materials lamination, different ratios of resins are taken as lamination material. For instance, for Bopp to
pp woven fabric lamination, perfect ratio is 3PP:1PE, but for Kraft paper to PP woven fabric lamination,
the perfect ratio will go to 3PE:1PP. Temperature setting on extrusion dies needs to be adjusted
accordingly as well. Coating and lamination quality is depend on the controlling skill on temperature
setting, coating pressure setting, and coated material peeling off strength.

4. Printing.

There are two typical types of printing method for pp woven sacks.

1. Flexographic Printing.

It is a printing method which uses flexible printing plate and transmits ink through the screen roller. It is
a kind of relief printing technology, which is called as flexo printing also. The picture and text part of the
flexible printing plate is raised. During printing, the screen roller evenly applies a certain thickness of ink
layer to the graphic part of the printing plate. Then, under the effect of the pressure of the press roll, the
ink layer of the picture and text part is transferred to the surface of the substrate to form a clear picture
and text.

2. Rotogravure Printing.

Gravure printing is a direct printing method, which directly imprints the ink contained in the concave pit
on the substrate. The thick and light level of the printed picture is determined by the size and depth of
the pit. If the pit is deep, there is more ink, and the ink layer left on the substrate after the imprinting is
thicker; On the contrary, if the pit is shallow, the ink content is less, and the ink layer left on the
substrate after imprinting is thinner. The intaglio printing plate is composed of a pit corresponding to
the original text and the surface of the plate. When printing, the ink is filled into the pit, the ink on the
surface of the plate is scraped off with a scraper. The plate has certain pressure contact with the
substrate, and the ink in the pit is transferred to the substrate to complete the printing.

Gravure printing, as a printing technology, has played an important role in the field of printing packaging
and graphic publishing, because of its thick ink layer, bright color, high saturation, high printing
resistance, stable quality of printing products and fast printing speed. From the application situation,
gravure printing is mainly used in fine publications such as magazines, product catalogue, packaging
printing, banknotes, stamps and other securities, and also in special fields such as decorative materials;
At present, gravure printing is mainly used in soft packaging printing in the international market. With
the development of gravure printing technology, gravure printing has been widely used in paper
packaging, wood grain decoration, leather materials and drug packaging. Of course, gravure printing also
has limitations, its main disadvantages are: the pre printing technology is complex, the cycle is long, the
plate making cost is high; Because of the use of volatile solvent, the harmful gas content in the
workshop is higher, which is harmful to the health of workers; Gravure printing practitioners require
relatively high treatment.

5. Cutting & Sewing

In the initial development stage of woven bag production industry, bag cutting and sewing are divided
into two separate steps. With the development and updating of technology and production equipment,
the cutting and sewing processes of woven bags have gradually merged into two different units on a
machine.

1. Cutting

The woven bag cutting is divided into heat cutting and cold cutting.

1. Heat cutting. For those woven bags that are not been laminated, a high-temperature blade
should be used to cut the bag while ironing the cut tapes to avoid scattering.
2. Cold cutting. That is to cut bags with a blade at room temperature, is only for those woven bags
that have been coated. The cold cutting process does not require heating blades, so the power
consumption is less.

2. Sewing

Now a day, the sewing thread is polyester thread which was made by cotton. Different thickness of the
sewing thread, needle pitch would affect the strength of the sealing. Customer could choose to use
single stitch or double stitch on the bottom of the bags.

The sewing and cutting machine is a type of all-in-one machine, it may integrated with functions of
sewing, cutting, gusseting, liner inserting, handle punching or even top hemming. Among the complete
manufacturing process of pp woven bags, sewing and cutting machines offers functional options for
different bags’ applications.

6. Baling.

Packing volumetric directly decides how much freight would be the freight cost for shipping, different
type of baling machines offers different pressures on packed pp woven bags, the more pressure it offers,
the less volumetric could get. This logic makes Hydraulic type of baling machines popular in current
markets.
After baling, the complete manufacturing process of pp woven bags has been done and it’s been ready
for shipping.

Masterbatch and Additives for PP Woven Bags Production

Considering the production cost or some functional purpose, in addition to polypropylene, which
accounts for the largest proportion of the raw materials of pp woven bags, additives such as
masterbatch, whitening agent, UV ray retardant and flame retardant are added. In order to increase
the chemical stability of polypropylene and reduce the production cost to a certain extent, the addition
of masterbatch is an important part of woven bag materials. Manufacturers have been looking for a
perfect balance between tensile strength and production cost when producing and designing woven
bags, In other words, according to the actual use of customers and the procurement budget to find an
optimal balance.

Filling masterbatch is one of the main ingredients in the raw material ratio of woven bag. Its main
function is to stabilize the physical properties of wire drawing. At the same time, because the price of
filling masterbatch is far lower than that of polypropylene, the addition of masterbatch can reduce the
cost. With the increase of filling amount of filling masterbatch, the tensile strength of wire drawing will
gradually decrease. Because the main component of filling masterbatch is calcium carbonate, there is no
tensile strength. A small amount of filler masterbatch dispersed in the gap of polyolefin polymer chain
has little effect on the drawing tensile strength, but the drawing stiffness is improved. It is more suitable
to control the amount of filling masterbatch in the range of 8% ~ 12% in order to make the woven bag
products achieve better use effect in the actual production process.

Plastic woven bags are widely used in industry and agriculture. The addition of fluorescent brightener
can make the recycled plastic woven bag whitener and brighter. Woven bag drawing is an important
step in the production process of woven bag. Recycled PP is granulated, drawn and woven into recycled
woven bag. Generally, the ash content of recycled PP plastics is relatively large, and the appearance of
bopp plastic bags is seriously affected by the dark color. Manufacturers usually add a certain proportion
of fluorescent whitening agent before wire drawing and hot melting, so as to increase the whiteness of
woven bags. The fluorescent whitening agent absorbs the invisible ultraviolet yellow light and reflects
the blue light in the plastic woven bag drawing process, so that the finished product can achieve a
whitening and brightening effect through the optical principle. It is generally recommended to add 200
grams of whitening agent to a ton of plastic. The amount of whitening agent used by different
manufacturers and brands is different.

Mission:

Xxx packaging is grateful and commit to service customers with the best solutions to make their
products with beautiful looking and better conditions of storage. Moreover, it aims to be a
reliable packaging supplier and we are always working on balance the production capacity and
operation cost, save every cent for our customer.

project--on-the-production-of-woven-pp-bags

https://www.verifiedmarketresearch.com/product/pp-woven-sacks-market/