Tape Plant Operations

Induction Report Submitted on April 2010 Submitted to Submitted By Mr. Vikas Sinha Sunil Verma Sr. Manager MarketingManagement Trainee- Marketing Flexituff Intternational Limited Flexituff Intternational Limited Departments visited 1. HRD 2. Tape Plant 3. Multifilament 4. HDN Loom 5. Needle Loom 6. Lamination/Liner 7. Q/A Sample 8. FIBC 9. Store Flexituff International Limited is a private limited company having its manufacturing facility at SEZ, Pithampur. It is the largest Manufacturing facility of PP Woven Sack in the world. Certifications attained by FLEXITUFF

ISO- 9001:2008 (For the manufacturing facility) ISO- 14000 (For the Environment) ISO- 9000 (Quality) ISO- 22000 (Fabric) HRD The HRD department here takes care of a lot of activities- • Recruiting new staff • Appraisal/Salary/ Incentive/ performance Appraisal • Preparing Daily Attendance • Preparing/ Disbursing Salary • Preparing a change in the process/ machine. • Motivating employees and so on. Products The products manufactured by Flexituff International Limited are as follows- FIBCs (coated/uncoated) Form Stable Baffle Bags Form Fitted Liner Bags

Glued Liner bags Conductive Type C Bags Dissipative Type D Bags Type C +D Bags Sling Bags Drum Bags Asbestos bags Container Liner Bags Food Grade Bags Tunnel Lift Bags Builder Bags PP / Paper Sandwich Bags Sand Bags BOPP Printed Bags Garden Waste Bags Carry Bags 1. Tape Plant There are 5 tape plants in the SEZ Unit. The production capacity of which are as follows- Capacity shown is of one shift (8 Hrs. ) 1. 2600 Kg. of Tape 2. 2300 Kg. of Tape 3. 1600 Kg. of Tape 4. 1000 Kg. of Tape 5. 3500 Kg. of Tape Process-Flow Diagram- Tape Plant

The raw materials are mixed in the hopper/ mixer machine (the proportion depending upon the quality of bag as required by the client) Then they are passed through a barrel where the mixed material is then heated to melt form this is followed by the Screen changer machine. This screen changer machine then separates the impurities through a filter. The melted material is here converted into a very thin layer, which is required to cool at 38(C, which is done by passing the film by a tank of cold water. This film is then passed through the Tape Extruder machine, which cuts the film into the required segments.

This film is now passed through the cutter, which again cuts the film into the required tape as required by the client this tape passes through 1st Godet also known as the rollers. These rollers elongate the tape, which is now passed through the hot oven to provide the tape the required properties as required in the tape at 156(C. The tape coming out of the hot oven is passed though the 2nd and 3rd Godet and they are further cooled in air to 40(C and finally they are collected at the Bobbins as a roll. Raw Materials include- CaCo3 (Calcium Carbonate) this provides the stretching quality of the tape.

LDPE/ HDPE- this material provides the softness in the tape. LDPE (Low Density Polyethylene)- Used when low strength bag is required HDPE (High Density Polyethylene)- Used when high strength bag is required. UV (Ultra-Violet)- Added to protect the bag from the harmful UV rays of the sun. The UV rays when exposed for a prolong time deteorates the strength of the bag. PPA- Polypropylene Additive- The composition of these above materials differs from product to product as per the requirements of the customer. Tape terminology- Denier Strength Width of the tape Spacer Size Stretching Ratio

Annealing Ratio Bobbin Size 2. Multifilament Tape Plant It is only tape plant that is used to get twisted tape in the facility. The twisted tape provides strength to the bags as they are used in stitching and hamming of the bags. Process-Flow Diagram- Multi-Filament Tape Plant. 1. Mixer: The raw materials are mixed here 2. Screen Changer: filters the impurities, if any. 3. Tape Extruder: extrudes out the tape in the form of a thin film. 4. Die Head: Presses the tape out from a very thin aperture of size 0. 5mm, at a temperature of 260(C and the potential is at 1900 Volts 5.

Chiller: Cools the hot film through a cold-water tank. 6. 1st Godet: Tape rolls out at a temperature of 85(C from here. 7. Hot Oven: The tape is again heated here at 116(C. 8. 2nd Godet: Tape rolls out at a temperature of 84(C from here. 9. 3rd Godet: Tape rolls out at a temperature of 84(C from here. 10. Winder: Threads are formed here through the winder. 11. Bobbin: Tape is collected here. 12. Twisting Machine: The tape collected through the bobbin is twisted in the twisting machine to provide strength. 3. HDN Loom HDN Stands for Hedal Drive Number. They are used to prepare bag cloth from the tape.

There are 59 looms in SEZ plant having a total production of 400- 500 meters in a single shift (variable as per the requirements) Terminology Size- According to the requirements of the client. Mesh- The total number of tapes in one sq. inch of the warp and weft is called mesh. Warp- the vertical tape that is required to make mesh is called as Warp. Weft- The horizontal tape that is required to make mesh is called as weft. Indication- These are the color-coding used to indicate the bag cloth is called indication, there are 8 of them being used in the facility.

GSM- It refers to the gram per square meter of the bag cloth, the higher is the gsm higher is the bag strength. HDN loom is tracked by the RMD, known as the Roll Management Department. 4. Needle Loom The final products of this needle loom are the loop, which is used for holding the woven bags. The raw material used here are the Tape and multifilament tape wrapped in the bobbin. The client uses the multifilament tape to provide the color as required in the loop. 5. Lamination/ Liner There are two plants of Lamination in SEZ. Lamination is manufactured from LDPE (Low Density Poly-Propylene) and Repol.

Liner Plant The Liner plant is used to manufacture the liner, which is used in the inner side of the bag. The liner is not necessarily kept in every bag, as it depends on the requirements of the client. Types of liner 1. Formfit Liner 2. Bottlshaped Liner 3. Suspended Liner 4. Gusseted Liner 5. Bottom sealed Liner 6. Flat Bottom sealed Liner 7. Open Liner 8. Baffle Liner Colors provided in the liner- a) Natural b) Milky White c) Blue d) Black Raw Materials- Liner LDPE (Low Density Polyethylene) LLDPE (Linear Low Density Polyethylene) PPA (Polymer Processing Additive)

Slip Master batch (coloring Additive) HDPE (High Density Polyethylene)/ PPE Sample Department The orders to manufacture woven bags are first sent to the Sample dept. , where the first sample of the bags are made and then sent to the client for further approval. After approval from the client, the actual production starts. If there is any problem/defect in the sample then again the woven bags are prepared and sent for approval. The sample department also designs the woven bags according t the client’s requirements. Types of bag order received according to the design are Circular • U panel • 4 Panels QA/ QC This department looks after the testing of the samples, to adhere to the quality standards set up in the industry and match with the best in the world. QA Dept. – It stands for the Quality Assurance department, which takes care of meeting the required quality before the actual production. QC department- it stands for controlling the Quality during the actual production process. There are various machines to look after the Quality required by the clients to match up these; various tests are done on the samples.

Load Testing Machine- It tests the maximum safe working load that the bag can handle. Electronic Tensile Tester Machine (Fabric)- It tests the maximum tensile load that the fabric can handle prior to tearing off. Fabric Bursting Machine- It tests the maximum load on which the load will be bursted and hence indicating the safe load capacity of the fabric. Electronic Tensile Testing Machine (Belt)- It tests the loop for the tension so that the maximum safe working load can be found. Liner Tensile Testing Machine- It checks the Maximum tensile load that the Liner can handle without tearing off.

Melt Flow Index Tester- It Measures the ‘mfi’ for the raw materials that are mixed and are in the molten form. Dart Impact Test Liner- Impact test is done by this machine for the liner. QUV Machine- It measures the UV compatibility of the fiber. 8. FIBC The FIBC Manufacturing Process. Bag Terminology Body Fabric- The fabric of the complete bag is called the body fabric. Side Fabric- The side fabric of the bag. Top- The top of the bag. Bottom- The bottom of the bag. F-Spout- Front opening for discharge of the material from the bag. D- Spout- Discharge Spout from the bottom is called D Spout.

Loop- the loops are used to handle the bags. Label- the DOC- Document Pouch 9. Store Store is where the inventory is kept in optimum levels so that the production can run smoothly and efficiently. The material that is easily available in vicinity of the plant has a dead line of 7 days. Whereas the material received from distant location have a storage period of 15 days. The store manager keeps a track record of the entire inventory, and has alphanumeric coding to easily track them. They also track these materials through the Computer using software called ‘FACT’.

Any information of shortage of the material is first sent to the store manager and subsequently is sent to the Purchase Department. Calling the quotations from different companies makes purchases and the lowest bidder gets the order for materials. Recreation Plant The waste and the scrap material obtained by the different manufacturing processes are recollected and stored in the recreation plant. They are then re-created using moulding and then again converted into grains through a big machine known as the Recreation Plant. FLEXITUFF DTA

The other plant situated at Sector-1 is called as DTA (Domestic Trade Area) This is the first manufacturing facility of FLEXITUFF International Limited. It has all the same units as are there in the FLEXITUFF, SEZ. ———————– Mixer Screen Changer Tape Extruder II- Godet III- Godet Bobbin Hot Oven I- Godet Cutter 3rd Godet Mixer Screen Changer Tape Extruder Hot Oven 2nd Godet 1st Godet Chiller Die Head Winder Bobbin Twisting m/c Baling Roll Cutting Production Metal Detector Packaging Folding Nutting Air Cleaning Dispatching FMG Delivery