The production process of plastic ton bags is:
Raw materials->drawing->weaving->coating->cutting->printing->sewing->inner bag->inspection->sorting->packaging->warehousing.
In the above production process, drawing, weaving, coating, cutting, printing, inner bag, etc. are the main links that cause losses.
1. Drawing: This process is one of the processes with the highest consumption in the production of plastic ton bags. There are 4 links that cause losses:
(1) When the melt is extruded into a film, there are plastic sheets and plastic blocks that are not film-forming;
(2) When the film is cooled and cut into broken wires, there are hard edges on both sides;
(3) The waste wire in the waste wire compartment is sucked into the single wire after shaping and wound into the bobbin.
(4) The consumption of each change of different specifications, varieties, colors, and clear filters.
2. Weaving: This process also consumes a lot of consumption. Three processes generate consumption:
(1) When the monofilament bobbin rotates on the warp frame and needs to be arranged in order, the jumper and the buckle will produce hairy, floating and dirty silk;
(2) When the weft yarn is packaged and enters the circular shuttle, hairy, floating and dirty silk will be produced;
(3) Every time the specifications of woven fabrics with different widths and different units are changed, the consumption of monofilaments and single pieces in the front and back transfer process is generated.
3. Film coating: The film coating process is the second process with high unit consumption. Three small processes generate consumption:
(1) The burrs of single-piece ton bag fabrics need to be cut off after film coating;
(2) When the raw materials are melted and extruded, there are high-temperature plastic molten materials that do not form a film;
(3) Every time the specifications of different widths and different unit weights are changed, the consumption of single pieces and composite woven fabrics in the front and back transfer is generated.
4. Cutting: The cutting process is the third process with the highest unit consumption, and 6 factors generate consumption:
(1) The shapes of the inlet and outlet are different, and the unit consumption is different. For example, if the conical inlet is connected to the bag body, the material waste is greater. At the same time, it is also affected by the length of the inlet. The longer the inlet, the greater the unit consumption;
(2) The consumption of the bag body. The bag cover on the bag body is connected to the upper inlet. The larger the size of the inlet, the more wasteful the bag cover fabric needs to be dug out. Similarly, the size of the bottom cloth cover and the lower inlet are also one of the factors affecting the unit consumption;
(3) Spacer bags. The spacer bags are to prevent the bag body from bulging after loading goods, affecting transportation and storage, and saving space. Each spacer has many holes. To facilitate the smooth flow of logistics, the size and number of holes dug are the most consumed parts;
(4) The consumption of round bags is also relatively large. Not only do the inlet and outlet holes need to be dug in the bag cover and bag bottom, but the cover and bottom also need to be cut into a circle, which makes the unit's consumption even greater;
(5) The consumption of slings and knotted belts is relatively small. Generally, this is because the weaving machine has a small amount of consumption, such as hair and floating silk when threading the palm and buckle when changing varieties;
(6) All the running around is due to the use of professional automatic production equipment. Once the wire breaks or the machine stops due to a fault, there will be an inevitable time difference, which will affect the quality of the base materials, such as woven fabrics and belts. Therefore, the base materials with inferior quality must be removed during cutting, which will also cause consumption.
5. Printing: When printing patterns or texts on ton bags, there will be consumption in terms of positioning, proofreading and ink color.
6. Inner bag: The consumption of inner bags is mainly due to the uneven blow molding control, which produces the consumption of the excess parts cut out.
7. Sewing: The sewing thread consumption used in the sewing process of ton bags is very small and can be ignored.