How to start Woven Sacks Production Business in Nigeria

As the demand for durable and eco-friendly packaging solutions continues to rise, understanding how versatile PP woven sacks are crafted has never been more crucial. Woven bags manufacturing process involves using premium polypropylene (PP) resin to create durable woven fabric, which is then printed, cut, and stitched into bags of various styles and sizes.

Market Potential: The major users of woven sacks are fertilizer, sugar, animal feeds, and cement. Starches, pesticides, detergents and many other industrial bulk items are also being packed in woven sacks. HDPE strips also used for deck chairs, etc. PP strips used for marine rope manufacturing.

With the introduction of circular looms, cost of production has come down drastically and making these sack more preferable now. Demand is ever growing with more and more factories preferring woven sacks for packaging. 90% of the production is consumed in the domestic industry while a little is being imported to border countries. With small and medium scale industries/ agricultural projects springing up, the demand also increases.

The market cuts across the whole parts of the country and neighboring African countries.

Manufacturing Process: First the tape is produced through the tape extrusion machine.

This tape is fed to knitting machine to form cloth on circular weaving machine.

Cloth thus formed is cut to required dimensions and stitched to size.

Printing is also done as per requirement and plan according to IS standards to meet customers’ requirements.

Location of the Project

The project can be located in any part of the country either in the Northern and Southern Nigeria.

Project Estimation

Unit runs on single shift 25days per month; Wastage of raw materials estimated is around 2%; Number of bags per kg depending on the density used; uninterrupted power availability is assumed, therefore there should adequate arrangement for power generating set and other alternatives to power..

450MT production capacity is estimated to be economically viable for a small scale industry.

Raw-Materials: 40T HDPE/PP granules; printing accessories; packing accessories. These raw materials are all available within the country.

Utilities: The project requires 300kva generator set, 11kva transformer; Electricity & water

A typical process is as follows: Pre-press preparation: Specialized graphic design software is used to create text, images, and logos that will be printed on the PP woven bags. Once the design is finalized, it’s converted into a format that can be used for printing, such as a digital file or a plate.

Plate creation: If traditional flexographic or gravure printing is used, plates need to be created. These plates are typically made of metal or other materials and are engraved or etched with the design. The plates are then mounted onto the printing press.

Ink prep: Ink is mixed according to the required color and viscosity specifications.

Printing: We then feed the woven bags into the press, where the ink is transferred onto the bags using the plates or other cylinders. This is repeated until all the different colors or layers of ink are applied.

Dry-cure: The ink is cured or dried after each application, depending on the method used.

Post-press finishing: After printing we use heat-setting to cure the ink and improve its durability and apply a varnish or coating for added protection or glossiness.

Quality control: Throughout this process, our QC measures ensure that the printed PP woven bags meet the desired color accuracy, print clarity, and other specs. Any defects or issues are identified and addressed to ensure a high-quality finished product.

Cutting: Cutting the material can be done by either hot or cold cutting: Heat Cutting

Heat cutting melts and seals the PP woven fabric edges to create clean and sealed cuts. The general heat-cutting process for PP woven bulk bags is: Preparation: The woven fabric is first laid out in multiple layers, and the bag panels are aligned according to the desired bag size and shape. The layers are stacked and held together securely to prevent movement during cutting.

Tool setup: A heat cutting tool, such as a hot knife or a heated wire, is set up and adjusted for the desired temperature and cutting depth. The temperature is controlled to ensure precise cutting without causing excessive melting or scorching of the fabric.

Quality control: We ensure that the cuts are accurate, clean, and free from defects. This involves checking for proper cutting depth, sealing quality, and bag integrity.

The biggest difference between the two processes is the elimination of heat during cutting. Instead, a knife or blade is used to mechanically cut through the fabric without applying heat.

One of the benefits of cold cutting over using heat is the reduced energy consumption for the manufacturer. However, this can only be applied to material that has been coated.

Cold cutting also reduces the risk of fraying, which can compromise the bag’s strength and durability. Even so, this doesn’t mean that heat cutting causes a weakness, since we ensure all our bags maintain the same integrity levels.

Packaging: Once the bags pass the inspection, they’re packed in our secure and controlled environment. This involves stacking the bags, bundling them together, or packing them in boxes, bales, or pallets, depending on the customer’s needs. Proper packaging is important to protect the bags from damage during transportation and storage and to ensure they are ready for distribution or sale.

Labeling:  Depending on the specific requirements or regulations, the bags are labeled with relevant information, such as product details, brand name, size, weight, safety instructions, and other necessary information for identification and traceability.

Financial Implications

The cost of the project depends wholly on the scale the investors want to run for a start. Generally, the feasibility studies will be carried out, putting the proposed location into consideration in determining the actual cost of establishing the proposed project. You can run the project on small, medium and large scale.

Investment Analysis

Payback Period: Within 2years

Rate of Returns on Investment: 40.4 %

Break Even Point : B.E.P 55.0%

Profitability: The project is very profitable and raw materials could be obtained within the country.

Get our Practical Guide on how to start Woven Sacks Production Business in Nigeria. Detailed structure of the production processes, Including personnel and manpower requirements, Plant layout, Raw materials sourcing, Marketing Techniques etc, will be embodied in a Comprehensive Feasibility Report for interested investors. 

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