Manufacturing Infrastructure & Plant

Step 1: Polymer Extrusion

High-Tenacity Tape Extrusion Lines

Using 100% prime virgin PP/HDPE polymer granules and color/UV masterbatches, our extrusion lines melt, cast, orient, and wind micro-uniform flat tapes with minimum denier deviation and supreme tensile tenacity.

• Capacity: 350 MT / Month Polymer Throughput
• Denier Range: 600 Denier to 2200 Denier
• Online thickness gauging and auto-tension winders

Step 2: Circular & Flat Looms

48+ High-Speed Circular Weaving Looms

Our plant houses 4-shuttle, 6-shuttle, and 8-shuttle circular weaving looms operating 24/7. Capable of producing tubular woven rolls from 12 inches up to 100 inches layflat width, with anti-skid diamond textures and colored identification weaves.

• Weave Density: 8x8 to 14x14 mesh counts per inch
• Zero-oil contamination magnetic shuttles
• Automatic weft break optical sensors with continuous electronic monitoring

Step 3: High-Definition In-Line Printing

BCS 6 Colour Online Flexo Printing Machine

Integrated directly with our high-speed conversion flow, the BCS 6 Colour Online Flexo Printing Machine provides synchronized, high-speed multi-color printing on tubular woven fabric rolls. Delivers razor-sharp brand graphics, micro-text, QR codes, and multi-color agricultural/industrial branding with zero smudging.

• Color Configuration: 6-Colour Precision Flexo (Front & Back 6+0 / 4+2 setup)
• Printing Speed: Up to 120 – 150 Meters / Minute with hot-air drying chamber
• Micro-Registration: Electronic mark sensors ensuring pinpoint print accuracy
• Eco-Friendly Inks: Non-toxic, food-grade compliant inks for feed & food packaging

Step 4: Automated Bag Conversion

BCS Cutting Machine (Lohia Bag Conversion System)

Our Lohia BCS Cutting Machine delivers automated high-speed bag conversion from woven rolls. It integrates precision heat cutting (anti-fray seal), synchronized mouth opening, single or double bottom folding, and multi-thread heavy chain stitching in one seamless automated pass.

• Production Output: 35 to 45 finished bags per minute continuous speed
• Cutting Dimensions: Bag length 500 mm – 1400 mm • Bag width 300 mm – 850 mm
• Optical Detection: Electronic eye mark sensor for printed fabric cutting precision
• Anti-Fraying Technology: Controlled temperature hot knife cut with automated batch stacker

Step 5: BOPP Lamination & AD*STAR Converting

Rotogravure Lamination & AD*STAR Valve Finishing

Equipped with multi-color roll-to-roll rotogravure printing, high-speed corona surface treaters, extrusion lamination machines, and automated hot-air AD*STAR block bottom valve bag converting lines.

• Full photographic CMYK + spot color high-gloss BOPP lamination
• Automated hot-air AD*STAR block bottom converting (no glue/adhesive)
• Ultrasonic hem cutting and heavy safety-lock chain stitching

Plant Machinery Master Registry

Core Plant Equipment & Operational Capabilities

Machine Line	Make / Model	Installed Units	Operating Capacity	Key Application
Tape Extrusion Lines	High-Speed Micro Extruder	Multi-Line Plant	350 MT / Month	Virgin PP / HDPE Tape Extrusion
Circular Weaving Looms	4 / 6 / 8 Shuttle High Speed	48+ Active Looms	5,000,000+ Sacks / Month	Tubular Woven Fabric (12" - 100")
BCS 6 Colour Online Flexo Printing Machine	BCS High-Speed Flexographic	In-Line Automated	120 - 150 Meters / Min	6-Colour Front & Back Roll Printing
BCS Cutting Machine	Lohia Bag Conversion System (BCS)	Continuous Automated Line	35 - 45 Bags / Min	Thermal Cut, Hemming & Chain Stitch
Rotogravure BOPP Lamination Line	Roll-to-Roll Multi-Color Gravure	Dedicated Facility	High-Gloss Photographic	Feed, Fertilizer & Retail Sacks
AD*STAR Valve Bag Converting	Hot-Air Welding Conversion	Block Bottom Line	Zero-Leakage Sealing	50kg Cement & Dry Powder Sacks

Quality Assurance Lab

Rigorous Batch Testing Protocol

Every single production lot undergoes 5 stringent laboratory tests before dispatch approval.

Tensile & Elongation

Calibrated UTM testers verify wrap and weft breaking tenacity.

Drop Impact Tower

Multi-angle drops from 2.5m height to guarantee zero burst in handling.

Accelerated QUV Chamber

2,000+ hour continuous UV exposure testing retention of polymer strength.

Air Permeability

Precise air venting calibration for rapid cement & powder packing.

World-Class Manufacturing Infrastructure