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PROJECT REPORT
I has been assigned to conduct and analyse project on Production of Flexible Intermediate

Bulk Container (FIBC) bag. The overall process of this production include nine stages in which
the procedure start with extrusion, weaving, webbing, lamination, helper/cutting, printing,
sewing, quality check/assurance and ends with finishing.
The first stage which is extrusion used polypropylene (PP), calcium carbonate (CC),
masterbatch (MB) and ultraviolet (UV) as their main raw materials. Polypropylene is the main
raw material with model number of HP456J from Titan Petchem (M) Sdn Bhd or other supplier
company from Saudi Arabia. Calcium carbonate, masterbatch and ultraviolet are an additives to
enhance the performance of the main raw material itself. Calcium carbonate act as filler
meanwhile ultraviolet of model number MB783-10 assist in protecting bag from harmful effects
of UV rays, thereby protecting it from degrading and becoming unstable and unsafe. Another
additives which is masterbatch with model number of CPM00313 for colouring raw polymer; the
available colour are white and beige. The overall unit and process involved at the extrusion can
be summarise as below:

Container

Hopper

Heater &
Filter

Cutting
Unit

Oven

Stretching
Unit

Water
Quench
Unit

Figure 1:Unit and Process involved in Extruder

The proportion of raw materials that are being fed to the container with ratio
97%:1%:1%:1% of PP:CC:UV:MB. The heater operate at 225C while water quench unit
operate at optimum condition ranging from 32 to 41C. The final product can produce different
size of yarns such as 2.1mm, 2.8mm and 5.0mm yarns depending on the type of fabrics to be
produced.
The second stage is weaving process in which yarns that are produce previously from
extrusion process are being used to make fabrics for body, top, bottom, spout and duffle of a bag.
Two types of equipment used are 4 shuttle machine to produce light duty product for spout and
duffle also 8 shuttle machine to produce heavy duty product for body, top and bottom.
The third stage is webbing process in which 2.1mm or 5.0mm yarns that are produce
previously from extrusion are being used to make rope or stalk for the bag. The production can
produce webbing with size of 20mm, 50mm, 80mm and 100mm webbing rope.
The next stage is lamination process. Lamination is a process of coating fabric with
plastic multi-layered films. Lamination will produce a flawless finish quality fabrics such as for
heavy duty (i.e., body) and light duty (i.e., spout/duffle) fabrics. Raw materials that are being
used in this process are mixture of Polypropylene (PP) [model no: PP 701] & Low Density
Coating Polyethylene resin (LDC) [model no: LDC 800YY with ratio PP:LDC of 8:3
(200kg:75kg). Operation Condition used the temperature of 270 C (upon running) and 80 C
(for pre heating the roll).
Helper/Cutting stage followed after lamination process in producing FIBC Bag. This
stage are responsible for cutting fabrics as per size specifications and feeding the sewing
department with cuttings in bundles. The capacity is planned based on the daily feeding

requirement of the sewing lines. FIBC bag manufacturing in this stage includes following subprocesses:

Fabric relaxation
Fabric spreading/layering on cutting table
Marker making
Manual cutting by using knife, machine cutting, automatic cutting
Shorting and bundling
Inspection of cut components

During the printing stage, the production should follows standard operation procedure
that have been provided for each body part that need to be printed.
The seventh stage in producing FIBC bag will be sewing process. During this process, it
is crucial to ensure that all those stitches are neatly sawn and no defect detected during quality
check/assurance process later.
The final stages will be finishing stages in which bags that had already been checked
previously will undergo packaging process. The production for this FIBC bag depends on size
and demands from customer. Several option on weightage for production of each bags are
800kg, 1000kg and 1500kg.