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PP woven fabric bags sit at the core of bulk packaging for fertiliser, cement, food grains, sugar, animal feed and countless other commodities in India. A single PP woven sack can hold 25 kg, 50 kg or even higher loads without tearing. High tensile strength, low weight and resistance to moisture make this format a practical choice for industry.

The process behind these bags is precise. Every stage matters. A true PP woven sack bag manufacturer like Pashupati Group treats the bag as engineered packaging, not just stitched plastic. The following walk-through traces that journey from raw polypropylene granules to finished PP woven fabric bags ready for dispatch.

Step 1: Raw Material Feeding and Extrusion 

Polypropylene resin forms the base material. Virgin PP, recycled PP or a controlled blend is fed into an extruder along with colour masterbatch and performance additives. Heat in the range of 260 to 300 °C melts the mix into a uniform polymer mass.

The molten polypropylene is then pushed through a flat die to form a thin sheet. That sheet is rapidly quenched in a cooling water bath to lock in its structure. The cooled sheet is slit into

narrow tapes. Each tape is drawn under tension at high speed to align polymer chains. This stretching step raises tensile strength sharply and gives the tape the load-bearing behaviour needed for industrial sacks.

Tape line output is monitored for width in millimetres, denier and elongation. Consistency here is non negotiable. Any variation in tape thickness or strength will show up later as weak fabric zones, seam failures or uneven print surfaces.

Step 2: Circular Weaving of the PP Fabric

The stretched PP tapes move to circular looms. A circular loom interlaces warp and weft tapes into tubular fabric. High precision looms running 4-shuttle, 6-shuttle or higher configurations produce fabric rolls at controlled picks per inch. The pick count controls density and therefore load capacity and leak resistance.

The woven tube can be produced in different diameters to match required bag volumes. For example 500 mm lay-flat width supports common 50 kg agro sacks. Heavier-duty industrial sacks demand tighter weaving patterns and higher GSM fabric. Mechanical wear on loom components, shuttle alignment and breakage rate of tapes are watched closely. Poor loom health creates skipped weave points. Skipped weave points create failure points under drop-test conditions.

This woven roll is the backbone of PP Woven Fabric Bags. Strong, flexible and lightweight.

Step 3: Laminated and Unlaminated Options

Two broad formats exist in the market.

1. Unlaminated woven sacks
2. Laminated or coated woven sacks

Unlaminated sacks allow breathability. This format is widely seen in grain and feed applications where ventilation matters.

Laminated sacks receive a thin poly coating on the outer surface. A PP or LDPE film in the range of roughly 15 to 30 GSM is extrusion coated onto the woven fabric. The film seals the weave, blocks moisture ingress and gives a smoother, more printable surface. This style is common in fertiliser, cement and chemicals where moisture control and clean branding carry high value.

Coating lines run at controlled temperature and line speed so that the bond between film and woven base remains even across the width of the roll. Poor bond leads to delamination.

Delamination in turn weakens shelf appeal and can cause print scuffing during long-distance transport.

Step 4: Printing and Branding

PP woven fabric rolls, laminated or unlaminated, move next to printing. Flexographic printing remains common for PP woven sacks, including high volume agro and industrial SKUs. High precision flexo setups can deliver multi colour artwork, brand blocks, technical data and regulatory markings.

Clear branding matters. A fertiliser sack on a dealer’s floor must stand out from 10 other sacks in the same 50 kg class. Consistent ink adhesion, colour density and registration accuracy build that presence. Inaccurate registration produces shadowed logos and blurred type, which can weaken trust in the product inside. For this reason, curing, ink viscosity and drum alignment are checked continuously during long production runs.

As PP Woven Fabric Manufacturers In India scale up to pan-India supply, a single artwork often needs to run in multiple language panels. Clean execution at this stage protects brand credibility in every regional market.

Step 5: Cutting, Stitching and Functional Finishing

Printed or plain tubular fabric is then cut to bag length, often in the 600 mm to 1100 mm range depending on intended fill volume. Cutting machines deliver heat-cut or cold-cut edges. Heat cutting seals the cut edge to prevent fraying.

Bottom stitching comes next. Industrial stitching lines use high speed sewing heads to create a secure bottom seam. Single fold, double fold or fold plus safety stitch can be specified depending on load requirements. A fertiliser sack for 50 kg urea demands different stitch parameters compared to a lightweight rice sack.

Optional features can be added at this point:

• Valve tops for valve bags used in cement filling lines.
• EZ-open tape systems for fast tear-open at retail or farm level.
• Liners for enhanced moisture barrier, inserted and stitched in place.
• Gusseting for better stackability on pallets and in godowns.

Each of these details brings real-world function to the finished sack. A PP woven sack bag manufacturer with in-house cutting and stitching control can tune these features per sector without external conversion delays.

Step 6: Quality Control and Testing

Quality for PP woven fabric bags is not only about burst strength. Real quality control looks beyond the lab.

Key checks include:

• Tensile strength of both warp and weft directions.
• Seam strength at the bottom stitch.
• Drop tests from 67 cm or higher with a 50 kg fill.
• UV stability for outdoor storage.
• Print rub resistance under simulated transport conditions.

Sample sacks from each batch are filled and dropped repeatedly. Failed seams, slipped stitches or tearing at punched ventilation holes are flagged before dispatch. Bag weight per piece is also recorded. A consistent grammage protects both the buyer cost structure and the filling line calibration.

Scale, Sustainability and Application Fit

Demand for PP woven fabric in India continues to grow year after year, driven by fertiliser movement, cement infrastructure, food grain logistics and animal nutrition supply. Reusability also plays a part. A strong woven bag often completes multiple trips in the field before disposal. Reuse across 2 to 3 cycles is common in the agri channel.

Recyclability forms another pillar. Polypropylene material from used sacks can be recovered, washed, reprocessed and sent back into extrusion. This loop reduces landfill pressure and supports more responsible use of polymer resources. Large integrated PP Woven Fabric Manufacturers In India with recycling and compounding capability under one umbrella stand in a better position to close that loop.

The Pashupati Group position in PP woven packaging

Pashupati Group operates across recycling, polymer processing and packaging production, enabling control from raw PP and recycled PP feedstock all the way to stitched and printed PP woven sacks. Vertical strength of this kind allows consistent tape quality, tight weaving standards and reliable stitching performance across high volume orders.

Custom PP woven fabric bags for fertiliser, cement, agro commodities and industrial powders can be produced with specific GSM ranges, coating thickness, stitch patterns, colour branding and regional language artwork. End users receive bags built for actual field handling, not just

showroom appearance.

This integrated model places Pashupati Group in the space occupied by leading PP Woven Fabric Manufacturers In India. The role covers PP woven fabric output, laminated sacks, printed sacks and heavy duty stitched sacks for bulk products. In other words, not only fabric supply but also fully finished sacks, ready for filling, stacking and transport.

A dependable PP Woven Sack Bag Manufacturer must deliver strength, print clarity, moisture control and consistency at scale. Pashupati Group aligns production, recycling and conversion to deliver that standard.