Injection Moulding
Blow Moulding
Blow Moulded Tank
Film Application
Pale Container Application
Extrusion Application
Woven Sack Application
Woven Sack /
Raffia Applications
Bajaj Provides all types of Masterbatches & fillers required for woven sack/raffia Application. We do offer products solutions that involves Cost Optimization, Quality Consistency & Enhancement of properties required for the end product.
Advantages
They are naturally resistance to tearing. woven sack bag could be printed on either one side or two side. These bags have better burst strength and any other plastic bag. Bajaj Masterbatch provides customized products as per customer requirements.
It is most widely used for packaging in bulk commodity, and it is flexible. woven fabrics are very strong that’s why woven sack bag will be used multiple times.
PP raffia is a widely used packaging material made from weaving thin strips / tapes of polypropylene. It is named after the raffia palm, which the packaging emulates to some extent. Polypropylene raffia is considered to be a “widely used material for atmospheric capture”.
Raffia is commonly used to produce industrial packaging, such as cement sacks, fertilizer sacks , polymers , chemicals and commodities packaging of food grains. The polymers used for its manufacture are High-density (HDPE) & Polypropylene (PP).
Woven fabric of PP , HDPE is made from thin strips / tapes that have been woven in 2 directions ( warp & weft) to create a light weight but heavy duty material which is strong enough to withstand heavy loads.
Having built with circular woven fabric ( PP / HDPE) one side is sewn as the bottom leaving the other side open , bags are done with various sizes depending on application requirements.
Why Bajaj ?
Quality Consistency
In spite of the polymer prices keep fluctuating , the addition of our filler yields better cost benefit ratio with quality consistency & higher loading.
Cost Benefit Ratio
Yields economical advantages to the manufacturer in terms of Cost Benefit ratio upon adding our filler with polymers in Tape plants with loading upto 60% on Polymer but not compromising on the product quality at any given point of time.
Increases Output
Increases output through production efficiency as the CaCO3 used in our formulation has good thermal conductivity to shorten the time required for each production cycle.
Improved Conversion Rates
With higher output rates and improved conversion rates, addition of our fillers results in increased operating efficiancies , all of which positively impact the bottom line of raffia manufacturer
Smooth Surface Finish
With exclusive combination in our recipe , we ensure good compatibility of polymer resin with CaCO3 filler it provides smooth surface finish to the end fabric as the dispersion is uniform while processing.
Unique features
The use of calcium carbonate fillers for raffia also make woven fabric be more well-in-shape in the thermal processing phase as it increases the stability during the manufacturing process.
With low dust formation , moisture , contamination free and batch to batch consistency , we strive hard & ensure to get away from process defects such as water carrying , tape cutting, etc
Our fillers provides faster heat transfer and the needed energy to heat up or cool down the mixture lower, this facilitates ease in processing at tape plants.
It reduces anti fibrillation/anti split agents. It also increases tape stiffness and opacity.
It’s eco friendly and food grade compliant as per the norms prevailing globally.
Facilitates improvements in Heat deflection temperature, bend resistance , impact strength, sealability & printability to add value to the end product by all means.
It also reinforces mechanical properties such as Tensile strength, Elongation , tear resistance, etc in the woven fabric enables ease of storage & transportation .
Increase tape elongation and strength
No more water carrying issue
No powder formation
No tape breakage
High line speed low denier
Higher filler loading
Types of RAFFIA / Woven Sack
TARPAULIN
A tarpaulin is a large sheet of strong, flexible, water-resistant or waterproof & fire resistant material, often cloth such as canvas or polyester coated with polyurethane, or made of plastics such as polyethylene (LDPE & HDPE) . LDPE tarpaulin sheet is mainly used as a protective covering from harsh weather conditions for domestic and industrial purposes.
FIBC / JUMBO BAGS
A flexible intermediate bulk container, jumbo, bulk bag, super sack, big bag, or tonne bag is an industrial container made of flexible fabric that is designed for storing and transporting dry, flowable products, such as sand, fertilizer, and granules of plastic.
LENO BAGS
Leno weave (also called gauze weave or cross weave) is a weave in which two warp yarns of Polypropylene are woven around the weft yarns to provide a strong & sheer fabric. The standard warp yarn is paired with a skeleton or ‘doup’ yarn; these twisted warp yarns grip tightly to the weft which causes the durability of the fabric.
Geo Membrane
A geo membrane is very low permeability synthetic polymeric membrane liner or barrier used with any geotechnical engineering related material so as to control fluid migration in a human-made project, structure or system. They are made of (un)reinforced polymeric materials which are used to stabilize earth & secure landfills ensuring containment of hazardous or municipal wastes and their leachates.
Advantages of Using Bajaj Rafia Solutions
Woven Fabric is strong
Woven cloth is flexible
Enhanced Strength
ease of storage & transportation
Resist tearing
food grade compliant
Uses of woven sack
- Agriculture
- Feed Industry -Storage & Transportation of feed products
- Construction
- Food
- Flood Control
- Tourism & Transport
- Geotechnical Packaging
- Chemical Packaging – Storage of crystalline & powdered chemicals
- For Military Fortification like trenches and bunkers And many more
Manufacturing PP Woven Sacks
The Process of involves following steps:
The process of manufacturing PP woven bags involves mixing raw materials starting with PP or HDPE pellets and other additives, extruding the raw materials into a yarn PP resin is heated with feeler of CaCo3 and pigment, melted and extruded as a flat film. It is then slit into tape yarn by the slitting unit and stretched and annealed. Next, a take-up winder winds the heat oriented tape yarn onto a bobbin.
Trouble shooting guide
| PROBLEM | POSSIBLE CAUSES | SOLUTIONS |
|---|---|---|
| FILM PUNCTURE | Hold up particle | Change screen pack. Check Row Material Moisture. Check heat stability of master batch. |
| GELES, HARD OR UNPLASTICIZED PROFILE | Improper back pressure. Improper temp gradient. Moister in master batch. | Change temp. Profile. Use fine wire mesh. Reduce die lip opening. Reduce adaptor flow area. Change screw geometry. Pre-dry master batch. |
| DENIER VARIATION | Extruder surging. Film thickness variation across width. Spacer thickness variation. Improper drive Performance. | Refer problem III in general extrusion processing. Reduce throughput rate. Increase die volume. Adjust die lip. Check uniformity of die temp. Check spacer thickness. Use carbon steel blade. Check drive performance. Check temperature of orientation unit across width. Check flow velocity of hot air across width. |
| TAPE BREAKAGE | Excessive stretch ratio. Low orientation temp. Hold up particle in film. Very stiff film. Extruder surging | Increase stretch ratio. Increase orientation temperature. Refer problem of film puncture and gels, hard or unplasticized particles. Increase distance between die opening and water levels in tank. |
| LOW TENACITY / HIGHER ELONGATION | Low stretch ratio. Too soft film. Low orientation temp | Increase stretch ratio. Increase distance between die opening and water level in quenching tank. Increase orientation temp. |
| TAPE FABILATION | Tape too stiff Scratches on tape moving path. | Use anti fabrillation MB. Polish tape moving path. Use wear resistance material items. |
| SHRINKAGE IN FABRIC / CURVED TAPE | Residual stress in tape. | Check annealing system. Increase annealing temp. Check cooling efficiency of roller. |
Bajaj solutions for woven sack industry
PLAST FILLER MASTERBATCHES SERIES
Our Filler range improves many product properties like Strength, Stiffness, Whiteness & Gloss, helps in reducing the production cost. Under Filler range we have 20+ products developed for woven sack.
Plast modifier
It is a property modifier masterbatch formulated in PE carrier resin that acts as processing aid & excellent bonding agent to enhance the properties of PP Compatible with a wide variety of polymers and resins & Recycled Polymers. It increases mechanical properties in highly filled mineral and recycled polyolefins specially made for Woven Fabric/Sack, Jumbo Bags ( FIBC). We produce our modifier masterbatches under our plast modifier series
Technical Features :
- Improves Whiteness
- Excellent Gloss, Shine & Luster
- Improves Dispersion
- Minimize Denier Variation
- Increase Strength
- Increase Elongation
- Increase Output
- Minimize formulation costs while enhancing end-product performance
- Less tape breakage with higher filler loading
- Faster line speeds and improved output
Plast white
It is a PE base filler , that is used for cost saving of polymer production, increase output, give better productivity, reduce machine wear & tear,save energy, and lower total cost.We produce our plast white filler under our plast white series.
Technical Features :
- Excellent anti-fibrillation
- Improve denier control of tapes
- Improve Anti-slip property
- Improve tenacity of tapes
- Improve film stability even at high speed
- Improve to print-ability
- Improve to heat resistant
- Improve productivity
- Impart Anti-blocking effect
- Improves whiteness hence saving of pigment
- Less abrasive to extruder & loom parts
- Cost reduction
Plast stiff
It is a pp base filler, which is used to reduce the cost of polymer,provide better productivity, reduce machine wear and tear,save energy, reduce wastage of products like woven sack, pp fabric, pp tape, tarpaulin, injection molding, food container, etc. we produce Plast Stiff under our ‘Plast Stiff’ series.
Technical Features :
- Excellent anti-fibrillation
- Less powder formation
- Improves Dimensional Stability
- Improves stiffness
- Anti-slip property
- Improves tenacity of tapes
- Improves cloth stability
- Better Heat Resistant
- Improves print-ability
Bajaj Plast Super / Tio2 series:
We have more than 20+ approved White/Tio2 Masterbatches for woven sack industries. It is used for giving white colour to the product. It’s a premium opacifying grade for the woven sack to comply with food regulations. It also reduces the addition level of UV additives.
Features:
- Highly loaded (up to 75 %) premium TiO2 Masterbatches
- Food grade
- Good dispersion and process ability.
- It has highly weather abilities like weather-fast and non-yellowing, non pinking varieties (with bluish tinge).
- High refractive index
- Light scattering efficiency.
Bajaj Plast Additive Series
Bajaj Plast UV
Need UV-protection for your Woven-sack products? We’ve got you covered! Our UV range is available for both Food Grade and Non-Food Grades, based on Hindered Amine Light (HAL).
In general Plastic woven sack are sensitive to sunlight, it’s exposure to UV radiations causes degradation of plastic .
In general Plastic woven sack are sensitive to sunlight, it’s exposure to UV radiations causes degradation of plastic .
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Our Plast UV masterbatch based on Hindered Amine Light Stabilizer (HALS) helps to extend durability of plastic products exposed to UV (Sun) radiation. This is the only product to sustainably decrease the reaction of degradation of plastic products which results in long life of the products. Plast UV are offered in food grade and non – food grade applications. Our UV Masterbatches can be used in production of Cement Bag, pp fabric, Laminated Bag, Tarpaulin,Fertilizer Bag, PP bag etcTechnical Features :
- Synergistic combination of oligomeric high molecular weight HALS
- Protects plastics from Photo degradation and long term heat exposure
- Low volatility, low migration and good resistance to extraction
- Low gas fading and low pigment interaction
- Suitable for applications requiring indirect food contact compliance
Plast Anti-Static
It is used to eliminate the developed static charge in plastic products. Polymers and Plastics are inherent insulators in nature and thus when subjected to triboelectric environments can accumulate electrostatic charge on their surfaces.
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This happens when polymers are subject to friction with other materials of similar or dissimilar nature (for e.g. metals) or their separation from other surfaces. When the charged polymer surface comes in contact with a neutral or oppositely charged surface (including humans) there is a possibility of spontaneous electrostatic discharge. A range of anti-static masterbatches can be offered depending upon the expected service life and level of surface resistivity reduction desired (usually resistivity of 109 Ohm/ Sq is achievable with regular antistats, we are working for 108 Ohm/Sq), relative humidity levels during use, regulatory requirements e.g. food approvals and criticality in post-processing such as surface printing and treatment.Features :
- Efficiently reduce resistivity.
- Long-acting anti-static effect.
- Performance will not be decreased by wiping or exterior friction. Good compatibility with various general & engineering plastic.
- Excellent dispersing ability.
- Pellet form, will not produce dust pollution.
- Reduce state charge of products, prevent electric shock.
- Increase added-value of products
- Resistant to water. Can still eliminate the buildup of static electricity
Plast Desccicant Masterbatch
BAJAJ PLAST DESICCANT Masterbatches are provided in pellet form
with a high concentration of active agents and excellent dispersion into the
end product.
Benefits of using this product include:
Residual moisture removal
Solves and avoids problems during the process such as: fisheyes,
holes and grooves
Key Benefits :
- Reduction-elimination of moisture in recycled and reclaimed polymers
- Reduction-prevention of moisture related problems including:
- Lacing in films
- Porosity
- Windows / lenses in films
- Die build-up
- Surface defects in moulding
- Reduces surface defects such as
- lensing and fisheyes in films
- bubble breakage
- voids
- pin holes
- silver streaks in moulded articles
Plast Clear
Transparent Woven-sacks are mainly used in food packaging. It is used to enhance the transparent property and strength of the end-products. We produce transparent Masterbatches under our Plast clear series.
Plast Clear is a talc base and formulated in PE carrier resin that acts as a nucleating agent, enhances printing and stiffness with optimum transparency of PP/HDPE/LDPE/LLDPE & recycled polymers. It also retains the transparency of the finished product. It increases mechanical properties in highly filled compound .
Key Benefits :
- Retains transparency in finished products while improving properties
- Even flow in processing by maintaining uniform back pressure
- Reduce post shrinkage of film
- Improve stiffness
- Improve Flexural Rigidity
- Better Draw-Down
- Improve Film structure with anti black property
- Improve Print-ability
- Improves adhesive lamination in multilayer film
- Better Opacity
- Increase machine output
Bajaj Plast colour series
We provide tailor- made solution for colour masterbatch, we can develop colour masterbatches as per user demand , we have 180+ colour shades available, and are already approved by users. More than 100+ colour masterbatch are developed each month by our R&D team.
Are you a Woven-sack manufacturer? Use Bajaj Masterbatches for your products
