The next-gen packing
Indian cement industry is facing issue of seepage of cement from uncoated bags, which is currently used around 80 per cent in packing of 50 kg cement. At present, the cement manufacturers are using similar packaging sack for the costlier product along with grey cement (pillow type bag). But, in the last few years, many of the cement manufacturers have started using Block bottom valve laminated sacks instead of regular pillow type woven sacks.
For instance, block bottom valve sacks or laminated PP bags with micro-perforation are considered as premium packaging products at an extra cost. Also, the manufacturers have freedom of choices in terms of getting branding and visibility as these sacks (block bottom valve laminated sacks) allow printing of high-quality graphics. The other factors that are propelling the change of pillow type bag to block bottom bag (laminated) in cement packaging are better quality and consistent end-use performance, the possibility to reduce the loss of cement during handling, transportation and storage and the increased compliance with government policies of large public interest related to health, safety, pollution- control and environmental protection including reuse and recycling of discarded sacks.
For the packaging of cement two BIS standards are given to maintain specification and requirements:
IS 11652:2017: Textile-high-density polyethylene HDPE/ Polypropylene PP woven sack for packaging of 50 kg cement-specification third revision
IS 16709:2017: Textile-polypropylene PP weaved laminated block bottom valve sacks for packaging of 50 kg cement- specification.
Ways of packaging of cement
Cement packaging is done in following ways:
50kg valve woven bags: 80 per cent of production is packed in 50 kg valve cement bags
Bulk containers: These are used for packaging large volumes
Lohia as a global manufacturer
As a global machine manufacturer, Lohia can offer machines for making bag of both types, i.e. unlaminated pillow type and laminated block bottom type. Cement companies and bag producers have to invest more as a capital investment in machines, but the investment has worth seeing environmental and human health issues due to cement dust oozing from uncoated bag. Today, the company has a full range of machinery in each of the technology vertical to cover almost the complete range of end use application of the plastic woven fabric.
Machines required for making cement bags:
Tape extrusion line: We offer a comprehensive range of tape extrusion lines for producing high quality PP/HDPE tapes for a wide range of applications, such as GÇô woven and knitted bags, jumbo bags i.e. flexible Intermediate Bulk Containers (FIBCs), carpet backings, tarpaulins, geo textiles, agro textiles, wrapping fabrics, ropes and twines. Our tape extrusion lines come in two distinct series, LOREX and duotec. The LOREX series is based on the conventional single stage stretching system while the duotec series uses a unique double stage stretching system.
Duotec series tapeline have following advantages for Lorex series:high line speed at max. 600mpm, possible to use higher filler masterbatch without compromising tape quality, and patented technology.
Co-extrusion technology: New patented technology which produce coextruded three layer tapes enabling use of high filler MB/recycle in core layer. This will have following advantages: less tape breakage, lower dust and glossy appearance due to presence of outer layer with high polymer content recipe.
Tape winders: We offer a wide range of precision and step precision winding machines designed for winding flat or fibrillated PP/HDPE tapes across a multitude of specifications in terms of tape width and denier. The warp & weft bobbins produced can be used in both circular and flat looms. The winders are classified under three distinct series " CM/FM series, CE/FE series and autoroto series.
Circular looms: Lohia Corp offers a comprehensive range of circular looms for weaving light to heavy weight tubular or flat PP/HDPE fabrics for a wide variety of end applications. Our looms are available under four distinct machine models: nova, LSL, LENO and venti.
Coating machine: Lohia's lamicoat is designed for efficient and precise coating operations on tubular or flat PP/HDPE woven fabric. Both PP & LDPE polymer coating is possible, as is the simultaneous coating of both sides of tubular fabric, in a single operation. Coupling of an unwinding station to the standard machine, for additional substrates like BOPP film etc for lamination operations, is also possible.
Printing machine: Soloprint, Flexographic Printing Press combines Lohia Corp's domain expertise with the technological capabilities of Pelican Rotoflex. This 6 colour printing press, equipped with new generation electronics, is distinctively designed and precisely machined for an accurate and dependable performance over its long life.
Bag conversion lines: Lohia Corp's bag conversion line consists of machines which provide solutions for conversion of a wide variety of tubular fabrics into bags.
Different technologies are available to produce bags depending on their end use as well as the type of fabric. Our conversion line consists of two distinct machines, the Lohia bcs 850/45, bcs 1250/45 for making normal bags and the Lohia valvomatic & blokomatic for making valve type cement bags.
Valvomatic: Lohia Corp presents Valvomatic used for making pillow type valve bag in the cement industry, a one of a kind valve bag making machine that performs multiple operations in a single automated setup. More than 40,000 valve bags per day, which are perfect in terms of dimensional consistency and accuracy can be produced. This is also patented technology of Lohia and supplied more than 250 Machines to the market and many more to supply.
Lohia offers two types of machine i.e. one for cement bags and another is wider width machine which enables to process wide width bags to cater the market demand.Advantages of using Valvomatic over manual conversion: accurate valve dimensions, automatic conversion to valve type bags, saves material, manpower and less space requirement.
Constraints in manual conversion are no consistency in manpower as they are not available in harvesting and festive season, land area requirement is high in manual working, less bag dimensional accuracy and igher production cost.
Blokomatic: One of the most innovative technology "blokomatic" launched by Lohia Corp during K 2019 exhibition. We received impressive and remarkable feedback from visitors during the exhibition. Blokomatic is a high speed, reliable, efficient and fully automatic machine for conversion of laminated polypropylene woven fabric into block bottom valve bags without application of adhesive. The machine is provided with latest control engineering and high quality mechanical and electrical parts. This machine can run up to max. 120 bags per minute.
One of the major USPs of Blokomatic is automatic fabric inspection system. This is a revolutionary concept patented by Lohia to inspect fabric quality on some predefined parameters prior to final bag manufacturing. This avoids the production of rejected bags due to bad fabric quality and reduces the overall wastage. This system is installed in fully automatic valve block bottom bag manufacturing machine "Blokomatic". The fabric inspection is done online before the cutting of the fabric and defected fabric cuts are ejected during the running of the machine.
Block bottom bags are ideal for automated filling and packaging cement and act as a better substitute to paper bags. The rectangular-shaped BOPP Woven Block Bottom bags are produced without adhesives by heat- welding of the coating on the fabric. Being moisture- resistant and environment-friendly is the major advantage of these bags. The oozing of material from the bag which results in almost no pollution.
By Anvita Sarkari of Lohia Machines.