The manufacturing process of PP/HDPE woven fabric sacks is divided into various phases, the first being ‘Extruding’. In this phase, the raw material, i. e., PP/HDPE granules are transformed into the shape of PP/HDPE sheet. The granules are melted and then extruded into a sheet of plastic, which then passes through the water quench cooling system. The water quenching maintains the temperature of the sheet.
The extruded plastic sheets are cut into a tape of polythene through the second stage of process ‘Slitting’. The slitter functions with oscillating knife pack, which ensures vibration free cutting of the sheet into tapes. For the formation of tapes, the plant has its sophisticated and fully automated tape line machinery ‘DUOTEC’ installed.
In the third phase of ‘Stretching’, the slit tapes are passed through a hot air oven for stretching. Each tape is stretched between the first godet and second godet while it is hot. This phase makes the tapes highly tensile and imparts high strength. Further stabilizing and annealing of the tapes is done on a ‘Stabilization and Annealing Unit’.
The oriented and stabilized tapes are taken to the ‘Autoroto Unit’ for winding, the fourth phase of manufacturing process. This unit is also the first of its kind in Madhya Pradesh.
Now comes the fifth phase, ‘Weaving’, which is done on circular looms. The plant has fifty looms procured from Lohia Starlinger Ltd. The cheese bobbins filled with the tapes are fixed on the creels and passed through the various points on the circular loom to form wrap. When the loom starts, the shuttle moves round in circular movement while weaving the tapes into tubular cloth.
Now comes the ‘Printing and Cutting’ where the product and manufacturing details are printed on the fabric through online Flexo Printing, machines, which is again an automatic printing and cutting machines resulting into high quality bags.