Gunny bags, which are also known as burlap sacks, hessian bags or jute sacks, are one of the oldest and most trustworthy types of packaging.
The bags are not only strong, breathable, and eco-friendly, they help in storing and transporting grains, sugar, coffee beans, potatoes onions, fertilizers and even cement.
The worldwide movement toward ecologically friendly alternatives has given them increasing prominence in recent years as an environmentally friendly substitute for packaging made of plastic.
This article aims at presenting the whole process of gunny bag making from raw materials to finish, and quality control as well as challenges and futuristics for that industry.
Read More: Why to Start Manufacturing Industry of Gunny Bags (Jute Bags)?
What Are Gunny Bags & It’s Utilization
Gunny bags, which are an exceptionally durable type of bag, often used for carrying grain and are particularly hard to tear open. They are tough and biodegradable. Also these bags don’t “seal” air tight so your food will be able to breathe, even if you’re storing it for 3 weeks, no mold or odors getting in there.
They store and transport large quantities of products like grains or roots, keeping them secure. And today, gunny bags have found new applications in more than just farms. For one thing, shoppers have used them for groceries.
Brands also print their logos on gunny bags for advertising. Beyond that, crafters are using them to create trendy, country-inspired home decor pieces.
Raw Materials Used in the Production of Gunny Bags
The strength and quality of a gunny bag are mainly based on the type of raw material used.
- Fibres: Jute is the most widely used fibre. It is plentiful, strong and easily raised. Other fibers, such as hemp or sisal may also be added.
- Fiber Attributes: Fiber is graded based on strength, fineness and color. The better fibers yield finer, stronger exportable fabric.
- Supplement: Stitching thread, printing ink or waterproof coating may be applied at a later date.
Plant Setup & Economics
To make these bags, you will need a FEW things.
Machinery: Looms, spinning machines, cutters, stitchers, printers and laminators produce various kinds of bags for customers.
Manpower: You have to employ some skilled hands who can run the machines and check the bags. Skill is important here.
Location: Factories must be near fiber sources to lower costs and maintain a dependable, steady supply year-round.
Investment: Basic investment is required for small plants. Larger factories are more expensive, particularly if you want printing or waterproofing.
Profit: Skinny bags = Small profits Adding features such as a brand name or waterproofing fattens profits because people are willing to pay more.
Quality Control Measures
Inspection procedures are an integral part of the gunny bag production.
Strength Tests: Employees pull the bags. They stretch them out. They try to break them. The bags need to be able to carry heavy things. If a bag tears, it fails. They do not ignore the seams. They test the seams hard. Bags with flimsy seams are thrown away.
Fabric Weight: Each roll of fabric is checked by workers. They ensure that every bag turns out the same. The bag has to feel strong. It should not feel flimsy or lightweight. They want all bags to weigh the same. From batches of fabric that are weak, they throw in the towel.
Waterproofness: The waterproof bags are filled with water. They watch for any leaks. They don’t let a single drop slip through. Leakers go in the reject pile. Only those that remain dry advance to the next location.
Food Safety: They choose safe inks and coatings. No weird or harmful chemicals. They aim for the packaging to be food safe. If a bag looks unsafe, they discard it. They are not cavalier about health.
Defects: Any bags that fail a test are out. They do not save it. Workers just throw it away. They just want customers to have faith in their bags. Only the “strong and safe” bags make it to stores. All others get left behind.
Market Insights
There is widespread use of such gunny bags in agricultural products like grain, coffee, sugar, onions and potatoes. These gear-units are also in great demand however within the fertilizer and cement sectors. As the bans on plastic covers are implemented globally, there is more market for eco friendly gunny bags.
India and Bangladesh are the leading producers and exporters, but increasingly markets in Europe and North America are looking to gunny bags as a sustainable packaging solution.
Challenges & Risks
Some obstacles remain, however:
- Changes in Raw Materials: The price of fiber is influenced by the weather and farmers’ harvest.
- Competition from Plastics: Synthetic woven bags are less expensive, but not green.
- Cost of Labor: Higher reliance on skilled labor is expensive.
- Sensitivity to Weather Condition: Extremes, heavy rains or drought make the fiber unavailability and poor quality.
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Step-by-Step Manufacturing Process
The making of the gunny bags is a long process with all steps, one by one guarding the durability and quality of final product.
A. Fiber Cultivation & Extraction
It begins with jute planting. You plant the seeds. And wait for them to be big and strong, that is. When your jute plants are tall, and lush with leaves and new growth, it’s time to harvest the lot.
People cut the stalks. After that, you need to get the fibers out. So you toss the stalks in water. This process of soaking is known as retting. It makes the jute fibers more loose.
Once it’s retted, you pull out the fibers by hand. We clean them in order to take the dirt off. You will have to dry the fibers after you are done cleaning. The sun does a good job here.
After the fibers dry, they are sorted by type or grade. Those fibers, now you can use them to produce gunny bags. And that’s what the process is like, step by step.
B. Spinning & Yarn Preparation
First, workers card and comb the dried fibers. This clears out impurities and aligns the hairs in cleanly. Spinning machines then twist the aligned fibers into yarn. Moving to this stage will lead the final use of the material. The yarn can be as thick or thin as it needs to be for the purpose. Coarse yarn is
C. Weaving the Fabric
The cloth is woven from the yarn on looms. Plain or twill weaves are applicable, depending on the purpose. The fabric is rough and heavy-weight material by design to give the canvas bag structure and durability.
D. Cutting, Stitching & Finishing
They chop up the woven fabric into standard sizes of all kinds. Some are large enough to hold 50 kilos. Some can comfortably accommodate as much as 100 kilos. Then they rev up these industrial sewing machines.
Workers sew the panels together so everything holds tight. Their seams and edges are beefed up. That’s so the bag can stand up to some serious weight. In all likelihood, you could carry a person if need be.
They tend to top things off by hemming the edges. They occasionally include additional reinforcement at corners and along seams. That’s not all. There will be handles attached occasionally more often than not.
This will make the bag much more comfortable for carrying. So, each step makes the final product more powerful and useful.
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E. Optional Treatments
For added value and application gunny bags can be treated:
- Lamination: Coating or lamination with a layer of plastic or other material to make waterproof.
- Printing: The bags are printed with company logos, product information and also branding information.
- Dyeing: Bags can be dyed to customer requirements.
Future Trends & Innovations
Gunny bags keep pace with modern needs:
- Waterproof Lined: This will seal your items dry. Long canoe trips need not mean wet gear.
- Custom Print & Brand: Businesses personalize these bags and fill them with candy. Their logos pop. It’s wonderful for marketing and tracking.
- Mixeds Fabrics: Manufacturers mix synthetic fabrics with the conventional fabric. The strong, reinforced construction allows the bag to lightly stretch without breaking.
- Eco Wise: Organizations are targeting the use of more natural fibers, today. They avoid chemicals. People like eco-friendly options more.
- Diversification: Gunny is not for industry only. What you find now are reusable bags, cool home decorations and new-as-can-be products.
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Conclusion
Gunny bags manufacturing is an interesting mix of traditional fiber processing and industrial methods. A process from retting the fibers to weaving and finishing guarantees that the end product is durable, eco-friendly and useful.
As the world moves towards an environmentally-friendly packaging, the gunny bags have become a promising sector. Manufacturers those invest in quality, innovation and value-added features will continue to flourish in this new era of green-minded consumers. For more assistance to launch you business in this industry, contact us.
FAQS
Q1. How much can a gunny bag usually hold?
Most have a 50-kilogram capacity, while heavy-duty versions can hold up to 100 kilograms.
Q2. Can gunny bags be reused?
Yes. They can be used again and again if properly maintained.
Q3. Are gunny bags waterproof?
By default, they are not. But plastic cards can be water-resistant with lamination or special coatings.
Q4. What is the most used gunny bag in industry?
They are important in large quantities by agriculture, cement, fertilizer, sugar, coffee and food processing industry.
Q5. Are gunny bags eco friendly?
Made of natural fibers, its degradable and resistant to tear and puncture.