Extrusion is the heart of entire woven polymer processing value chain. We have an installed capacity of 1500 MT per month on its state of the custom made world-class Raffia Extrusion Lines. These machines are equipped with the best-in-class equipment from Siemens, Mitsubishi, Allan Bradley, ABB, Zimmer, Kolsite, and Lohia Starlinger. Our extrusion lines feature all the necessary attachments like melt pressure pumps, static mixers, capacitance gauging of film, automatic dosing mixing, direct silo-based feeding, Annealing & Quenching for low shrinkage conditioning. We are one of the few fully integrated plants in the world, which gives us the advantage of retaining a superior degree of quality assurance and allows us to customize our products exactly to your requirements.
We have a fleet of more than 100 circular weaving machines. These machines are in the range of 6-shuttle and 8-shuttle. All the machines are fitted with automatic tension control mechanism to monitor the weft breakage wastage and color censor-based mechanism for the warp breakage control. Our fleet is capable of weaving fabric in every possible size from as small as 14” diameter to as large as 82” diameter. Of course, should the need arise, we’re perfectly capable of weaving up to 164” lay-flat fabric. And all of this in a range that extends from 7x7 to 18x18 mesh. In fact, we weave 300 Km of fabric every day no different type of weaving machines.
Webbing is a very crucial stage in the construction of FIBCs. In order to make the bags more efficient we need to keep a very close watch over the production of webbing. We have over two dozen belt weaving machines. With an eye on customization of solutions, we’ve augmented ours with 90 heads of webbing machine. The webbing machines can weave webbing from 6mm to 90mm in size, and 60KGF to 3,000KGF in strength. Needless to say, this webbing can be completely customized in terms of patterns, colors and textures.
Creating a moisture barrio is a basic use of extrusion coating process. When your situation demands a coated product, we’re able to deliver. Thanks to our extrusion coating machinery. We have installed two extrusion coating lines with an installed capacity of 180 MT/month. Both the lines can deliver coated product solutions up to 2.2 meter wide; with an added capability of sandwich-coating that’s used for BOPP film coated bags and HDPE/PP coated bags. Our coating plants are fitted with automatic laser sensing and edge-trimming devices that allow for narrow edge trim cutting. Pre-heating for heavy gauge FIBC fabric and post lamination perforation / gusseting is a standard fitment.
3 Layer Co-Extruded Liner
We realized the need for providing weather-resistant transportation solutions early on. Which is why we went ahead and put up India’s largest liner blowing machine at our factory, with a liner-making capacity of 300 MT per month. This machine is capable of producing up to 5.2 meter lay-flat sheets, from 20 to 400 microns in thickness. Should your requirement demand it, we can make “form fit” liners that are fitted with the FIBCs either as a loose tab fitting or glued to it. In fact, we can also make antistatic, alufoil and even uncontaminated food-grade liners with the best possible barrier properties for your FIBCs, at the optimal cost.
Twisting and filler cords
We believe that a complete control on the entire manufacturing process is necessary if we are to provide our customers with totally customized solutions. Which is why, we have an in-house facility for fibrillating and twisting our own stitching yarn. Our twisting section can produce 2,000 kg of stitching yarn, from 200 to 8,000 Deniers in strength, every day.
Similarly, our in-house filler cord and tie cord section can manufacture cords from 2 to 6 mm in diameter. As we can produce the cords in polypropylene, we can ensure a complete recyclability of all our products.
The printing section is made 12 printing machines capable to serve different functions. We have 6-color automatic cutting and printing machine to deliver a variety of printing requirements for the PWS. These machines have the capability for corona treatment of up to 42 dynes. FIBCs section is complemented with five manual machines that are capable in printing from one to three colors in ranges up to 60” wide and 80” in length. We have an On-line “Roll to Roll” printing facility with repeat length up to 500mm. These machines are fitted in tandem with the extrusion coating plant and are capable to print up to 2.2mtr lay flat with in maximum 2 colors.
Here’s where the fabric we weave and the webbing we make comes together in the final product. We operate four facilities for FIBCs at Silvassa. These four facilities allow us to make virtually every kind of FIBCs that you might require – circular as well as U+2 panel bags. The entire range – Type A, Type B, Type C, Conductive FIBCs, Baffle Bags, Single and Two Loop Bags, Garden Waste Bags, Pallet-less FIBCs, Woven and Film-type Container Liners, and many more – are all made in these facilities, with over 300 stitching machines and other support machinery working 24x7x365. All this makes our FIBC facility one of the best in the world.
Quality assurance lab
We have fully developed Quality Assurance Laboratory. The lab helps us to implement stringent “Internal Standards”. The lab has a measuring instruments and staff to check the tensile load bearing of all our components at every stage of operation. After checking all the individual parameters, we can check the fully loaded FIBCs in our state of the art in-house test rig. This test rig is equipped with independent load cells for each loop testing of the FIBC. This helps to produce completely defect free product for our customers. The automatic test rig has a facility to simulate the load pattern of the bag before putting the bags actually to use. Reducing the UV degradation is one of the challenging demands of the woven PP industry. In order to achieve this, we use Hindered Amine Light Stabilizer (HALS) based UV stabilizer. We have installed “ Q Lab-USA ” Weather-o-meter with automatic irradiation control and country specific testing facilities to ensure the effectiveness of UV stabilizers used. Detailed component-wise testing is done starting from single thread to fabric strips to webbings. Light selective color matching booth is used to match the exact colors as per the Panton/RAL reference. Dart Impact tester is used to find the resistance of the PP and PE Co-Ex films. This helps exact pinpointing in the design parameter. Also, it is capable of doing companion test.