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Technology for the manufacture of a mixture for the production of polypropylene bags. Polypropylene bags

The production of polypropylene bags is organized on modern compact production lines. The relevance of opening such a business is confirmed by the wide demand for finished products. Food and non-food bulk materials, construction and household waste need inexpensive, durable packaging for transportation and storage. Polypropylene packaging perfectly copes with such tasks, and the costs of creating such a production are quickly paid off.

The relevance of the production of polypropylene bags

Polypropylene bags are durable industrial packaging. It is characterized by resistance to abrasion, the possibility of repeated use, water resistance, versatility and low cost. Differs in the type of raw materials:

white bags made from virgin polypropylene. Used for transportation and storage of bulk food products: sugar, flour, salt, starch;
gray produced from recycled materials with the addition of virgin polypropylene. Less durable than white, suitable for transport and storage building materials and waste, pelleted feed, fertilizers and chemicals;
Green produced entirely from recycled materials. Slightly inferior to gray in strength. Used for the disposal of construction debris.

Industrial activities related to the production of PP bags are in high demand. The wide possibilities of such packaging and the low price allow it to be in high demand among construction companies, agricultural firms, representatives of the food and chemical industries.

Business strategy

Before organizing industrial production: rent a room, purchase equipment, hire employees, even at the stage of developing a business plan, it is worth analyzing the ways of implementation finished products. The main consumers of products:

Construction companies;
Industrial enterprises;
Retail Stores and wholesale bases;
Agricultural producers;
Farms;
Warehouse complexes;
Internet shops;
Dacha cooperatives;
Private entrepreneurs.

Any production is not complete without marriage. For the processing of waste and products that have worked out their time, there are special devices. The purchase of a crusher for plastic recycling and a granulator will help organize the process recycling polypropylene. Recycling- an important component of the environmental program for the disposal of industrial waste.

Business organization

Since the manufacture of PP containers is associated with the processing of polymeric raw materials, the location of the production workshop should be removed from residential buildings. The best option when creating a plant, it is considered the lease of a suburban premises with the possibility of its subsequent redemption into ownership.

When organizing production, mandatory technical requirements to the equipment of the workshop is the presence of:

Good ventilation system;
Necessary communications (water, heat and electricity, sewerage);
Cleaning air filters.

The amount of space required depends on the dimensions of the purchased equipment. On average, a production line occupies 50 m². It is necessary to provide storage facilities, rooms for staff, a garage if delivery of finished products is planned.

The domestic market has a large selection of machines for the production of polypropylene bags, machines and devices. You can choose the one that suits your power and price. The system of leasing equipment with subsequent purchase has proven itself well. The price of a fully equipped line with a capacity of about 4,000 items per shift will be at least 3,500,000 rubles.

For quality service, automated line for the production of polypropylene bags, at least six people are needed, three people in two shifts, with salary 25000 rubles per month.

Approximate amount capital investments as follows:

The cost of equipment is 3,500,000 rubles;
Delivery and installation of the production line - 350,000 rubles;
Purchase of granules - 320,000 rubles;
Registration in tax office, payment of monthly rent, overhead costs - 280,000 rubles;
Total - 4450000 rubles.

If you plan to organize a garage, you need to add at least 1,500,000 rubles to this amount.

The value of the constants monthly expenses is made up of:

Salaries of six employees - 150,000 rubles.
Social payments to the wage fund - 45,000 rubles.
The cost of renting a workshop is 110,000 rubles.
Administrative payments - 60,000 rubles.
Other expenses - 100,000 rubles.
Total - 465,000 rubles.

Technological stages

The main stages of production:

Mixing and drying of raw materials. Primary and secondary polypropylene granules are mixed with dyes and necessary additives. Often calcium carbonate is used. It gives the package a white color and the desired rigidity. The finished mixture is fed into a polypropylene extruder with a flat slotted nozzle and heated to 260 °C.
Production and winding of a flat thread. The heated mixture passes through the nozzle in the form of a thin film. After cooling, it is cut into flat threads of the required thickness, hardened, drawn and wound on coils.
Fabric production. The circular loom is adjusted to the required parameters: the thread weave density and width are set. The resulting polypropylene sleeve for making bags is wound onto large reels.
Cutting. The finished polypropylene fabric is cut into blanks by hot cutting. The cut line can be straight or wavy.
Manufacture of final products. A special device, from the bottom side, folds the polypropylene fabric for bags the required number of times and stitches it with a strong synthetic thread. The neck is left unfinished or stitched. In some cases, polyethylene liners are sewn to the bottom.
Logo laying on. The flexographic machine applies a polychrome or black and white logo to the finished product.
Package. Finished products are stacked in packs of 500 or 1000 pieces, pressed, tied with twine and stored.

Video: "Cutting and filing bags"

Necessary equipment for the production (manufacturing) of polypropylene bags

Standard production line consists of:

Machines for drying and mixing the components of the mixture;
feeding device;
An extruder for the production of polypropylene threads complete with a winding device;
loom;
Thermal knife for cutting blanks;
sewing machine;
Flexo printing machine for applying the logo.

Additionally, you can use a machine for laminating bags on one or two sides. There is an industrial apparatus with simultaneous lamination and multi-color printing on the film.

To dispose of defective products, purchase:

Crusher for crushing possible rejects and production waste;
Granulator. Processes crushed material into pellets for recycling.

To avoid problems with after-sales service, it is preferable to look for local suppliers.

Video: "Production of a polypropylene sleeve for bags"

Video: "Printing on a flexographic machine"

The payback period is calculated as the ratio of the amount of capital investments to the amount of monthly net profit: 4450000/255000=17.5. Thus, the company will be able to recoup the costs of organizing the production of pp packaging in about a year and a half.

Opening a mini-factory for the production of polypropylene bags is considered as a profitable investment. Given the wide range of applications, the products of such a plant are in high demand and quickly sold. Finished products do not require special conditions storage and are not limited by the expiration date.

Polypropylene is a mineral. The raw material for polypropylene is propylene gas (propene). Powdered polypropylene is dried, mixed with stabilizers, dyes and then granulated. As a rule, polypropylene is produced in the form of granules with a diameter of 2-5 millimeters (much less often a powder). PP belongs to the class of polyolefins. There are several subclasses of polypropylene, they are called grades. The most common grades of polypropylene are 21012 and 21015. The most famous trade marks- this is Balen of the manufacturer's plant Ufaorgsintez and PP, PP of the Tomsk petrochemical plant. Polypropylene is a thermoplastic, crystalline, isotactic polymer. Density 0.92 g/cm³, melting point 160-176 °C, relative elongation 200-800%. Stable in water and aggressive inorganic media (except for strong oxidizing agents), below 80 °C - in organic solvents (swells above this temperature). Polypropylenes are characterized by high resistance to repeated bending and abrasion, and relatively high impact strength. The maximum operating temperature is 120-140 °C.

Production of polypropylene bags

PP bags are made from polypropylene raw materials. The quality of the polypropylene used depends performance characteristics future bag. For production, primary or secondary polypropylene is used. Secondary is obtained by processing used products, including from used polypropylene bags.
Polypropylene raw material, usually supplied in the form of granules, is mixed with various additives and dyes. One of the most popular additives, calcium carbonate (chalk additive), is designed to give bags a milky white color. Additives are designed to set the properties of the future material for the manufacture of pp bags. This mixture is fed to an extruder, where it is heated to 260 °C and extruded through the channel of the extruder head, resulting in a thin film. After cooling, a thin polypropylene film is cut into strips - threads, which are wound on reels.
Bobbins with polypropylene threads are sent to the next workshop - weaving. Here the main material for the PP bag is made - polypropylene sleeve. The threads on the bobbins are threaded into a circular loom and a woven material is obtained by the shuttle method. At this stage, the loom is adjusted to the specific parameters of the future product. Its width and the presence of special anti-slip threads are determined so that the bags stacked on top of each other do not move apart during storage or transportation. The polypropylene sleeve is wound on large reels suitable for storage and transportation.
To get a pp bag, all that remains is to "cut" the sleeve into the desired lengths, sew the bottom and process the neck. This is done by a special line, which, using the hot cutting method (thermal cutter), quickly turns the polypropylene sleeve into blanks for the future polypropylene bag. Hot cutting is necessary so that the threads of the bag are melted to prevent spreading. Having cut off a fragment of the required length from the polypropylene sleeve, the machine tucks the bottom of the polypropylene bag the required number of times (usually once or twice) and sews the seam with a strong multifilament thread. According to a pre-programmed algorithm, the neck of a polypropylene bag may remain unprocessed, or, by analogy with the bottom, the machine makes the required number of turns and stitches the neck. The neck can be cut with a straight thermal cutter, zigzag or tucked and stitched.
In the production of a bag with a polyethylene liner, the liner is sewn to the top of the bag by seamstresses by hand, after the bags are cut from the sleeve and the bottom is sewn into them. The liner can be cut off and sewn together with the sleeve automatically, then it will be sewn not only along the neck, but also along the bottom. This requires special equipment.
In the production of laminated bags, a melt of polypropylene, polyethylene or their mixture is soldered to a polypropylene sleeve on one or both sides, forming a laminating layer that protects against moisture ingress, then the bags are cut to the desired length with a thermal knife and hemmed on a sewing-cutting machine.
A valve may be formed on the bag. It is made manually by seamstresses, if the bag is ordinary (stitched), and formed automatically on the machine, if the bag is box-shaped laminated.
Further, the bags are collected in packs of 500-1000 pcs. depending on bag size. Packs are pressed, wrapped with polypropylene fabric and fitted with twine.

Polypropylene bags from the manufacturer

The company "Staler" is a manufacturer of products made of polypropylene. The production lines in our factories are equipped with modern machines. Use of quality raw materials, special technologies and production equipment allows us to provide our customers with:

Quality.
Our company has been operating since 2009. During this time we have accumulated considerable experience and can guarantee the high quality of our products.

Price.
Our prices are among the lowest in our segment, we don't have markups, we don't like them as much as you do.

Confidence.
You can be sure that your order will be completed on time and you will never hear the phrase "Sorry, the supplier let us down, your order is not ready yet."

Convenience.
Our customer focus drives our policy. The main thing for us is mutually beneficial, professional, long-term and honest work.

How to order polypropylene bags

Have you already decided to buy polypropylene bags from the manufacturer? Great, this is the right decision! You can choose the method of communication convenient for you and place an order for the production of bags. phone, website, Email- You can use all this to place an order. You can even order a call back - in this case, our manager will call you!

Ready-made bags in large and small wholesale, the minimum lot is 1 pack or 2000 rubles. All standard items are always in stock. Let's make under the order any batch according to your sizes.

When organizing production for the manufacture of polypropylene bags, attention should be paid to the features technological process. You need to know that the release of such products should take place under conditions of increased requirements for the cleanliness of the premises, since the presence of even a small amount of impurities can lead to a change mechanical properties products.

The production of bags is a highly polluted process environment, therefore, additional requirements apply to the enterprise:

production premises must be located in a non-residential area;
the room must be equipped with an aspiration system for harmful substances and air filters for fine air purification;
it is necessary to have water supply and sewerage in the building;
it is mandatory to have an alarm for the excess of harmful substances in the air and a fire alarm;
electrical input to the building must be three-phase;
a separate protective ground loop is required.

In addition, all standard requirements of regulatory authorities apply to the production of polypropylene bags. The average area of the production workshop is small - about 60 m2. This allows you to place power even in small buildings.

Materials used in production

It is used as the main raw material in the manufacture of products. Other synthetic materials are not widely used due to worst performance or high cost. Polypropylene is distinguished by abrasion resistance and high heat resistance, which, together with chemical resistance to aggressive substances, has determined its widespread use as a material for the manufacture of universal packaging for bulk foods, fertilizers, salts and various chemicals.

Depending on the purpose of the final product, a variety of raw materials are used for the manufacture of canvas:

For the production of polypropylene bags intended for storage and transportation of bulk products (flour, sugar, salt, food products), primary polypropylene is used. It is also used for the production of big-backs (a flexible container for the transport of bulk materials) due to the high strength of the material. These bags are white.
For the production of polypropylene bags intended for transportation and storage of non-food bulk substances (agricultural feed, fertilizers, chemicals), mixed polypropylene is used. It is made from a mixture of virgin polypropylene and recycled materials. Bags made of this material are gray in color.
For the collection and disposal of construction waste, polypropylene bags are made, completely made from recycled materials. Such bags have less strength and low cost.

Manufacturing technology

Processing of secondary raw materials

A grinder is used to prepare raw materials from recycled materials. The main element in the installation is a drum that grinds the material to the required size. The installation is operated by one person, whose duties include monitoring the operation of the device, loading material for processing and monitoring the filling of the bunker with raw materials.

Drying of raw materials

In this production cycle, pre-drying is performed to prevent the formation of vapors in the heating hopper of the extruder. The procedure is carried out in an industrial oven at a temperature of about 80 C until the moisture in the original raw material is completely removed. At this temperature, substances harmful to human health begin to be released, so it is necessary to use an exhaust ventilation system for the equipment. The operation does not require constant human supervision, therefore, as a rule, this work performed by a worker serving the grinder.

Mixing of raw materials and production of fabric material

Raw materials are poured into the extruder and mixed in the receiving hopper, where, if necessary, a dye is added. Then the mixed raw material is fed into the heating tank, where a constant temperature is maintained, which is optimal for melting. At the end of the melting process, the heated mixture is fed through a slotted nozzle. In the process, a continuous layer of polypropylene film is obtained, which cools under the pressure of air.

The film is wound on a drum up to a certain diameter, after which it is replaced with a new one. To operate the machine, one worker is required, who monitors the film production process, the level of raw materials in the receiving hopper, and also removes the finished drums with polypropylene film.

Cutting film to obtain thread

The machine cuts the film into threads of a given thickness and winds it onto finished spools that are used in a loom. In the process of cutting, you should monitor the same thickness of the thread, if necessary, adjust the knives of the machine. To work on the machine, a qualified worker is needed who can quickly adjust the machine. His duties also include changing film drums and changing wound spools of polypropylene thread.

fabric making

For this, a circular loom is used, which produces a sleeve of the required size from a thread wound on spools. It is necessary to monitor the operating parameters of the machine:

weaving density;
bag width;
the absence of marriage in the canvas;
uniform thread consumption.

The finished sleeve is wound into a roll and transported for printing or further production of bags. This machine is notable for the complexity of setting up; for its maintenance, a specialist is needed who monitors the correctness of the technological process.

Image printing

A flexographic press is used for printing. The device uses special elastic dyes, which are supplied by means of a dosing device to drums with a printing plate for each ink color. The roll is fed through a system of rollers rotating printing forms with paint. In this case, the required pattern is formed. Finished products are wound onto a drum for further cutting and manufacturing of polypropylene bags.

The machine requires a person to monitor the print quality and load the print media. Attention should be paid to the synchronism of the print rollers in order to avoid marriage during printing.

Cutting, bag sewing and packing

A woven sleeve is fed into the bag making machine from a drum, which detects the location of the logo with the help of a photocell and cuts the sleeve to the required length. For cutting, a thermo-knife is used, which fuses the individual threads to prevent the fabric from unraveling. Then the fabric is turned up at the bottom of the bag and the bottom is sewn. The upper part can be stitched depending on the machine settings. If necessary, it is fed into the bag, which is sewn to the bottom of the bag.

Packaging of finished products is carried out in packages of 10, 50, 100, 500 and 1000 pieces, after which the products are transported to the finished product warehouse.

The article describes the organization of its own highly profitable production of polypropylene bags. The text is divided into subheadings: requirement for the premises, personnel, equipment, materials, production technology, business profitability.

Polypropylene bags are widely used in agriculture, construction for packaging building mixtures and materials, everyday life and household as an inexpensive, durable and easy-to-use packaging.

Polypropylene bags are widely used in agriculture, construction for packing building mixtures and materials, everyday life and households as inexpensive, durable and easy-to-use packaging.

Requirements for the premises

The starting capital for the implementation of the business idea will be about 160 thousand dollars. The main part of these funds will be spent on the purchase of equipment and the lease of premises; production and storage areas will require considerable sizes - 800-1000 sq.m. The shop has a number of requirements. The building must be at least 50 meters away from the residential area, the floor is concrete, the walls are tiled, ventilation, sewerage, heating systems are required, compliance with standards fire safety and labor protection rules. total area subdivided into several production departments(this will include a polypropylene yarn production workshop, weaving and cutting workshops), as well as amenity, administrative premises, warehouses for storing raw materials and finished products. preparation project documentation can be trusted to a third party. The cost of such services is estimated at $60 per sq.m.

PP bag making equipment

The cost of a new automatic line for the production of polypropylene bags of Chinese origin is on average 100,000 USD. excluding delivery and installation. It includes such main components as looms, cutters, printing presses for applying advertising images, a laminating machine, a machine for producing flat polypropylene thread of various thicknesses and widths, an extruder, equipment for processing plastic residues and waste after the manufacture of threads.

Polypropylene

Granules of primary or secondary polypropylene act as raw materials for the manufacture of bags from polypropylene yarn. The choice of suppliers of the latter is very wide. The purchase price of 1 kg varies from $ 1 to $ 1.5, depending on the quality of polypropylene and the degree of purification from impurities.

Production technology

Polypropylene granules in a special hopper are mixed with dye and additives. As the latter, calcium carbonate is used, which provides a beautiful white color and the necessary stiffness of the threads for the bag. The cost of the additive in bulk purchases is about $2 per 1 kg.

The mixed components enter the extruder, under the influence of high temperature the mixture melts and is squeezed out in the form of a thin film, after cooling it is cut into threads that are wound on the coils of a circular loom, and here the fabric base is formed - the sleeve of the bag. Then the fabric is cut with a cutter using the hot cutting method, the edges are edged or stitched, the neck is also processed. Finished products are stacked in packs of 500-1000 pieces, pressed to reduce the volume and transferred to the warehouse. Additional source income can be the use of the sidewalls of the bag as an advertising platform and the application of other images. This procedure is carried out using a flexographic printing press with the possibility of mono- or full-color printing.

Staff

To maintain the line, a staff of 2-3 workers will be required. Salary expenses will average 1800-2000 USD. per month.

Profitability of a business idea

The cost of manufacturing one polypropylene bag is estimated at $0.09. Wholesale price - $0.25. Given that 1 kg of granules can produce 14 finished products, the monthly profit of the enterprise can reach 7.5 thousand dollars with active sales and large deliveries to construction, agricultural, and agricultural companies.
Low cost materials, excellent margin, high demand for final product and the possibility of using recycled materials make it possible to consider the business of producing polypropylene bags as a promising, profitable and profitable direction activities.