What is a hdpe woven sacks project report?
An HDPE woven sacks project report is a detailed project report (DPR) for a unit that makes printed sacks from HDPE or PP granules. It covers tape extrusion, circular weaving and conversion, and sets out the process, machinery, raw materials, buyers, BIS approvals, project cost, loan structure, five-year projections, DSCR and break-even.
Entrepreneurs use a project report on HDPE woven sacks to size the plant and seek a term loan; banks use it to test repayment.
Also known as: HDPE PP woven sacks project report, woven sack manufacturing DPR, HDPE woven bags project report, HDPE woven sacks business plan.
What a bank checks in an HDPE woven sacks project report
A woven sacks plant turns polymer into packaging at a thin spread, so lenders look hardest at polymer cost and buyer credit. These are the values in our sample report and why each one matters.
Polymer, filler and masterbatch take most of each rupee of sales. A report showing a much lower share is usually overstating profit.
HDPE and PP prices move with crude and naphtha. The report should test a rise in granule price and show the DSCR that remains.
Cement and fertiliser companies pay against bills, not on delivery. Receivables are the largest current asset in the sample, so they drive the cash credit limit.
DSCR is the cash available for each rupee of loan due. The sample's weakest year is Year 2, when full instalments start; lenders check this year first.
Values are the assumptions in our illustrative sample. Your report uses figures for your capacity, buyers and suppliers.
How much does an HDPE woven sacks unit cost?
The biggest cost decision is whether you extrude your own tape or buy woven fabric. The right-hand tier is the plant in our sample report; the other two are indicative ranges.
Converting unit
₹30–60 lakh
Buys woven fabric rolls; cuts, prints and stitches sacks
- Machinery₹10–25 lakh
- Shed fit-out (or rent)₹8–20 lakh
- Working capital margin₹5–15 lakh
May fit PMEGP or Mudra, subject to limits
Small integrated unit
₹2.5–4.5 crore
About 1.5–2.5 metric tonnes per day, one tape line and 8–12 looms
- Machinery₹1.2–2.2 crore
- Land and building₹0.8–1.5 crore
- Working capital margin₹25–50 lakh
MSME term loan, often with CGTMSE cover
Mid-size integrated unit
₹720 lakh
4,500 kg per day, 14,85,000 kg per year
- Plant and machinery₹328 lakh
- Land and building₹245 lakh
- Working capital margin₹58 lakh
Term loan ₹540 lakh (75%), promoter ₹180 lakh
Converting and small-unit ranges are indicative and exclude land unless stated. Costs vary with loom count, lamination, machine make and location.
HDPE woven sacks plant economics in our sample
The sample plant makes 4,500 kg of sacks a day over 330 working days. It starts at 60% capacity, reaches 80% in Year 5 and sells at ₹167 per kg, excluding GST.
| Land and site development | 69.59 |
|---|---|
| Building and civil works | 175.48 |
| Plant and machinery | 328.43 |
| Other fixed assets | 47.29 |
| Contingencies | 25.20 |
| Preliminary and pre-operative | 16.15 |
| Working capital margin | 58.20 |
| Total | 720.34 |
| Promoter's contribution (25%) | 180.08 |
|---|---|
| Term loan from bank (75%) | 540.26 |
| Cash credit limit (separate) | 174.59 |
| Total project cost | 720.34 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. All figures are illustrative.
HDPE woven sacks manufacturing process
Sacks are made in six stages, from granules to baled sacks. Tape quality set in the first stage decides the strength of everything that follows.
- Tape extrusion
Granules, filler and UV masterbatch are melted and cast as a film, slit into narrow strips and stretched in a hot-air oven to give tapes their tensile strength.
- Circular weaving
Tapes wound on bobbins feed circular looms, which weave a tubular fabric with no side seam to the set width and mesh, measured in ends and picks per decimetre.
- Lamination
Where the buyer wants moisture protection, the fabric gets a thin extrusion coating of PP; cement and fertiliser buyers often ask for it.
- Printing
A flexo machine prints the brand, contents and weight, and for certified sacks the BIS standard mark with "HDPE woven sack only" or "PP woven sack only" below it.
- Cutting and stitching
Fabric is cut to length and the bottom is stitched. BIS requires stitching tape of at least 20% higher denier than the fabric tapes.
- Testing and baling
Sacks are checked for size, mass, fabric breaking strength and seam strength, then counted and baled with the batch and month of manufacture marked.
Raw materials for HDPE woven sacks
Granules are bought from petrochemical producers and their distributors, usually on short credit. Filler masterbatch lowers cost per kg, but too much of it raises ash content, which BIS tests on every control unit.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| HDPE or PP tape-grade granules | 80% | 853.46 |
| Calcium carbonate filler masterbatch | 8% | 85.34 |
| UV and colour masterbatch | 6% | 64.01 |
| Printing ink and stitching thread | 6% | 64.01 |
| Total | 100% | 1,066.82 |
Machinery for an HDPE woven sacks plant
The tape extrusion line is the costliest machine and sets the plant's daily output. Loom count is then chosen to weave everything the line makes.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Tape extrusion line | Melts granules, casts film, slits and stretches tape | 131.37 |
| Circular looms | Weave tape into tubular fabric | 98.53 |
| Lamination plant | Coats fabric for moisture resistance | 32.84 |
| Flexo printing machine | Prints brand, contents and marks | 26.28 |
| Bag cutting and stitching machines | Cut fabric to length and stitch the bottom | 22.99 |
| Baling press | Packs counted sacks into bales | 16.42 |
| Total plant and machinery | 328.43 | |
Costs are the sample report's estimates for a 4,500 kg per day plant. Get current quotations before you finalise.
Who buys HDPE woven sacks in India?
Most sacks go to bulk packers that buy in large, repeat orders through tenders or annual rate contracts. Each buyer type fixes its own sack size, fabric weight, mesh and print, so a new unit usually starts with one or two segments it can serve well.
- Cement plants and grinding units
- Fertiliser manufacturers and marketing companies
- Food grain procurement agencies and warehouses
- Sugar mills
- Polymer, chemical and cattle feed producers
- Packaging traders and distributors
Demand is seasonal for some buyers. Fertiliser sacks peak before the kharif and rabi sowing seasons, and food grain sacks around procurement months, so the report should plan stock for those peaks.
Where a new unit wins: sacks are bulky for their value, so a plant close to cement grinding units or fertiliser plants saves freight and can deliver at short notice.
BIS certification and licences for a woven sacks unit
As of October 2026, the BIS licence is the approval that most often decides whether you can supply a buyer at all.
| Business registration | Udyam (MSME) and GST registration. Woven sacks of polyethylene or polypropylene strip fall under HSN 6305 33; confirm the current GST rate with your CA |
|---|---|
| BIS for food grain, sugar and sand sacks | Licence required under the HDPE and PP Woven Sacks Quality Control Order, 2020, in force since 23 October 2020 (IS 14887, IS 16208, IS 14968, IS 14252) |
| BIS for cement sacks | A Quality Control Order for 50 kg cement sacks to IS 11652 has been notified and its start date postponed more than once; confirm the date in force with BIS |
| Raw material for cement sacks | Virgin HDPE to IS 10146 or PP to IS 10910, under the BIS scheme for IS 11652 |
| In-house testing | Certified units test samples through the day and send BIS a yearly production statement certified by a chartered accountant |
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board, which sets the category for your plant |
| Power | Industrial power connection sanctioned for the tape line, looms and lamination load |
Mistakes that weaken a woven sacks project report
- Pricing per sack without fixing sack weight
Buyers quote per sack or per kg against a set size, mesh and fabric weight. Revenue built without those specs cannot be checked by the bank.
- Loading too much filler
Extra calcium carbonate cuts cost but raises ash content and lowers strength, and a failed control unit has to be reprocessed or rejected.
- Tape line and looms out of balance
Too few looms leave the costly tape line idle; too many leave looms waiting for tape. Either way the output in the projections is not reached.
- Planning to reuse waste in cement sacks
IS 11652 sacks need virgin raw material. Start-up waste and trimmings must be sold or used in other products, and the report should value them that way.
- Leaving out BIS time and testing cost
The licence, in-house lab and sampling routine take time and money before certified supply can start. Missing them delays the first sales.
How NPCS helps you set up an HDPE woven sacks plant
- Sack type and capacityChoose cement, fertiliser or food grain sacks and size the tape line and looms to match.
- Machinery and suppliersCompare tape lines, looms and lamination plants and collect quotations.
- Bank-ready project reportProjections, DSCR and working capital in the format your lender asks for.
- BIS and approvals planThe IS standards, testing set-up and state approvals your sack type needs.
NPCS's client list includes 3 assignments for HDPE and PP woven sack projects and 24 in packaging, part of the project reports NPCS has prepared since 1994.
What's inside the hdpe woven sacks sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
18 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
Real NPCS hdpe woven sacks project reports
These are hdpe woven sacks project reports NPCS has prepared, with the plant capacity, total capital investment, rate of return and break-even worked out in each. Costs have moved since some were written, so we bring any of them up to date for your capacity and location.
| Project report | Plant capacity | Total investment | Rate of return | Break-even | Action |
|---|---|---|---|---|---|
| Hdpe/PP Woven Sacks | 10,000 Bags /Day | ₹3.92 crore | 45% | 39% | Get this report |
| Hdpe/PP Woven Sacks(Using Circular Looms) | 20000Nos. /Day | ₹5.25 crore | 30% | 61% | Get this report |
| Hdpe Woven Sacks | 71000 Nos./ Day | ₹6.63 crore | 26% | 59% | Get this report |
| Hdpe/PP Woven Sacks | 36000000 Nos. / Annum | ₹10.46 crore | 27% | 55% | Get this report |
| Hdpe/PP Woven Sacks | 2 Lakh nos. /Day | ₹17.94 crore | 28% | 52% | Get this report |
| Hdpe / PP Woven Fabric From Tape Line using Circular Looms and Sacks Making with Lamination of Bopp/ Bopet/… | HDPE/PP Woven Fabric: 7.2MT/day HDPE/PP Woven Bags for fertilizer: 102857 Nos/day | ₹25.36 crore | 21% | 57% | Get this report |
Figures as worked out in each NPCS report. Total investment includes plant and machinery, land and building, and working capital.
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HDPE Woven Sacks project report: frequently asked questions
What is the HDPE woven sacks manufacturing plant cost in India?
A unit that only cuts, prints and stitches bought-in fabric needs roughly ₹30–60 lakh. A unit with its own small tape line and 8–12 looms needs about ₹2.5–4.5 crore. Our sample report models a 4,500 kg per day plant at ₹720 lakh. These are indicative figures; your report works out cost for your capacity, sack type and location.
Which raw material is used to make HDPE woven sacks?
Tape-grade HDPE or PP granules are the main input, mixed with calcium carbonate filler masterbatch, UV masterbatch and colour. In our sample report the granules make up 80% of raw material cost. Cement sacks certified to IS 11652 must use virgin HDPE or PP, so plant waste has to be sold or used elsewhere.
Which machines are needed for woven sack manufacturing?
A tape extrusion line, circular looms, a lamination plant for coated sacks, a flexo printing machine, bag cutting and stitching machines and a baling press. In our sample the tape extrusion line is the largest item at ₹131.37 lakh. The number of looms must match the tape line output, or one of them runs idle.
Is BIS certification mandatory for HDPE woven sacks?
For several sack types, yes. A Quality Control Order in force since 23 October 2020 requires a BIS licence for HDPE/PP sacks for food grains, sugar and sand. A separate order for 50 kg cement sacks under IS 11652 has been notified, with its start date postponed more than once. Check the date in force with BIS before you plan.
Can I get a PMEGP or Mudra loan for a woven sacks unit?
A small converting unit can fit PMEGP, which covers manufacturing projects up to ₹50 lakh with a 15–35% margin-money subsidy. Mudra loans go up to ₹20 lakh under Tarun Plus. A plant with its own tape line usually costs more and takes an MSME term loan, often with CGTMSE guarantee cover. Limits change, so confirm with your bank.
HDPE woven sack ka business kaise shuru kare?
Start by choosing the sack type and buyer: cement, fertiliser, food grain or sugar. Then fix capacity, find a shed with an industrial power connection, get machinery quotations and apply for Udyam, GST, pollution consent and the BIS licence your sack needs. A project report with costs, projections and DSCR is what the bank asks for before a term loan.
Is the HDPE woven sacks project report PDF free, and can I use it for a loan?
The sample PDF is free to view and download. It is an illustrative report that shows the format and depth of an NPCS report. Its figures are representative and not based on a real project, so it should not be submitted to a bank. For a loan, NPCS prepares a report for your own capacity, sack type, location and loan scheme.
Sources and references
- Quality Control Orders on textile products (HDPE and PP Woven Sacks for Packaging or Filling QCO, 2020)Bureau of Indian Standards, checked Oct 2026
- Scheme of testing and inspection: HDPE/PP woven sacks for packaging of 50 kg cement (IS 11652:2017)Bureau of Indian Standards, checked Oct 2026
- Product manual for IS 14887:2014, HDPE/PP woven sacks for 50 kg food grainsBureau of Indian Standards, checked Oct 2026
- Notification No. 9/2025-Integrated Tax (Rate)Central Board of Indirect Taxes and Customs, checked Oct 2026
- Prime Minister's Employment Generation Programme (PMEGP)Bank of India, checked Oct 2026
- Tarun Plus category under Pradhan Mantri Mudra YojanaPress Information Bureau, Government of India, checked Oct 2026
- Credit Guarantee Fund Trust for Micro and Small EnterprisesCGTMSE, checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.