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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 woven sack products solutions like cost, quality & properties etc. 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.
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.
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

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

PROBLEMPOSSIBLE CAUSESSOLUTIONS
FILM PUNCTUREHold up particleChange screen pack. Check Row Material Moisture. Check heat stability of master batch.
GELES, HARD OR UNPLASTICIZED PROFILEImproper 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 VARIATIONExtruder 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 BREAKAGEExcessive stretch ratio. Low orientation temp. Hold up particle in film. Very stiff film. Extruder surgingIncrease 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 ELONGATIONLow stretch ratio. Too soft film. Low orientation tempIncrease stretch ratio. Increase distance between die opening and water level in quenching tank. Increase orientation temp.
TAPE FABILATIONTape too stiff Scratches on tape moving path.Use anti fabrillation MB. Polish tape moving path. Use wear resistance material items.
SHRINKAGE IN FABRIC / CURVED TAPEResidual stress in tape.Check annealing system. Increase annealing temp. Check cooling efficiency of roller.

Bajaj solutions for woven sack industry

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:

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 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 :

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 :

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 :

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 .
read moreOur 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 etc

Technical Features :

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.
read more 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 :

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 :

    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 :

    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

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