How to open an industrial production of plastic bags. Features of the production of plastic bags Own production of bags in-house manufacturer

To package sandwiches and fruits, the first packaging bag was made in America in the 50s. It turned out that this was convenient, and already in the 60s they began to sell bread in just such packages. Traditional “T-shirts” appeared on sale only in the 80s, but they have become popular all over the world since the early 2000s. And for good reason: the production of plastic bags is quite simple, the price of the product is low, and there are a lot of conveniences. Today we’ll “take a look” into the workshop and tell you how plastic bags are made.

Technology for the production of plastic bags

The production of polyethylene bags occurs in several stages:

• the extruder blows out a polyethylene “pipe”;
• the pipe is cut into pieces;
• glue the seams by welding;
• handles are cut out;
• drawing or coloring is applied on a special machine;
• After this, the products can be further laminated. Of course, this is not required for “T-shirts” and “packaging”, but for long-term options with handles and branded packaging it is important.

How the film appears

The polyethylene film from which the bags are made is produced by extrusion. First, polyethylene in the form of granular balls is loaded into the extruder hopper: there it melts at a temperature of 180-240 ° C, is pressed and blown through a round hole. The molten material rises under air pressure to the upper part of the extruder, where it is cooled and wound onto a drum. When the required footage has been wound, the film is cut and a new roll is started.

Important: if you immediately need to get an opaque film, then the dye is poured into the extruder hopper along with the granules.

Printing a drawing

To apply a picture or logo, you will need a machine: flexographic - for circulations of more than 3000 pieces or silk-screen printing - for circulations of 100 pieces or more.

What is the difference between silk-screen printing and flexography:

• A silk-screen printer applies a design using stencils, allowing you to quickly create bright and large images;
• The flexograph prints with highly elastic liquid inks. The machine consists of rollers on which soft polymer-printed forms are mounted. The dispenser supplies the paint, the roller is wetted with it, and then the drum starts rewinding the film. During rewinding, the film rotates the rollers, and they leave a bright, durable pattern on it.

The paint must be diluted with industrial alcohol and constantly stirred during operation so that it does not thicken.

Cutting and welding seams

The bag-making machine cuts the roll according to a given template, forms a fold on the side and on the bottom seam. A heating press at a temperature of 180°C seals these folds into the seams in just 2 seconds.

Sealing occurs according to a given seam size - this indicator is responsible for the strength of the bag, since the greatest load goes to the bottom.

Now the film has turned into a roll of blanks, and it is sent for cutting. To do this, the roll is pulled through an optical sensor: it marks the boundaries of each package, guided by the pattern and seams. Such a sensor is required when you need to apply logos or a certain picture in a certain part of the package.

A guillotine (hot knife) or a punching press cuts out products according to a template and also forms a handle. Depending on the template, the handles can be cut out; if this is the production of T-shirt bags, they can be cut to shape, for which a special attachment for the press will be required. The handles of “bananas” are reinforced: thick plastic of a similar color is soldered onto them.

That's all: finished bags are packed in 100 pieces, sent for quality control, and then to the warehouse.

To package finished products you will need plastic clips. To make them you will also need a special installation.

Equipment for the production of plastic bags

So, for a full cycle you will need the following machines for the production of plastic bags:

• extruder - “inflates” sheets 30-50 cm wide and 0.1 mm thick from polyethylene granules. Suitable piston, disc, single-screw and multi-screw extruders with a capacity of 40 kg/hour;

Warning: you can save money by buying a semi-manual machine and ready-made film, but in the end the cost of the finished product will be higher. With such a machine it will be possible to produce only “packaging” and garbage bags - you won’t be able to go wild with the assortment. Therefore, companies with full-cycle production often have cheaper packages than those of semi-handicraft workshops, and the product line is wider.

• a bag-making machine, which has a built-in heating and cutting press, thermal needles, a photosensor - will make cutting and cut out handles (“T-shirts”, “bananas”, packages with a plastic clip, etc.);
• flexograph - prints a drawing;
• machine for lamination, drying and making clips.

The service life of the machines is about 10 years, if preventative maintenance is done on time.

A plastic bag production line requires a workshop system that maintains temperature control. This is necessary so that the resulting sheet cools and hardens evenly.

The workshop should have ceilings of 8 meters and an area of ​​approx. 150 sq. meters. To protect the health of employees, powerful ventilation is needed, since when polyethylene melts, it releases aggressive volatile compounds. Therefore, the workshop building itself must be located in a non-residential or industrial area. Equipment, placement, systems and organization of workplaces are checked for compliance with GOST 12.3.002-74, 12.2.061-81 and 12.3.002-74.

Raw materials and suppliers

Raw materials for the production of polyethylene bags must comply with GOST 10354-82 (it is necessary to undergo quarterly certification, providing produced samples for examination).

The best polyethylene for the production of bags is spherical granules with a diameter of 3-5 mm.

What are plastic bags made of:

• high-density polyethylene (HDPE)- it is high-quality, non-toxic, intended for the food industry. Used for the production of polyethylene bags for packaging. It is used to make “T-shirts”, bags with cut-out and loop handles. The product does not tear even from sharp objects and does not crack from frost. Complies with GOST 16337-77;
• low pressure polyethylene (HDPE) - there are both higher quality options with approval for contact with food, and standard HDPE for storing dry and bulk products. Such products can withstand a lot of weight and are often used to make garbage bags. They are not afraid of frost and chemical reagents, they comply with GOST 16338-85.

Compared to HDPE, LDPE is softer, more flexible and more pleasing in appearance, with a matte surface. HDPE is stiffer, denser, not as transparent and rustles.

In addition, all granules are divided by type into first grade and recycled polyethylene.

Bags made from recycled polymer are of worse quality, they are toxic, and it is prohibited to put food products in them. Recycled raw materials are only suitable for the production of garbage bags.

Granular polyethylene grades 10803-020, 15813-003 and 15313-003, produced in Russia (Kazanorgsintez PJSC, Tomskneftekhim LLC) and South Korean production, are popular among manufacturers.

The manufacturing process itself is simple. The main thing is to work before production begins: do not skimp on automatic equipment and high-quality raw materials. Recycled polymers and semi-automation often result in high production costs and time expenditures, which negate any initial savings.

Included in the 2020 catalog. Companies have established production and wholesale sales. Prices are low and negotiable. 120 industry representatives have been added to the list. Well-known suppliers on the Russian market:

• "Foodupak"
• "Packetservice"
• "IndustriPack"
• "Lietpak"
• "GreenPak" etc.

The products are widely used for food packaging, storage and transportation. Packaging products are used in production, construction, trade, etc. Packages are supplied in rolls or in packs. Manufacturing material - polymer film. Range:

• polyethylene,
• vacuum,
• paper,
• packaging,
• with valve,
• with loop handle,
• T-shirt and other categories.

Companies have updated equipment. Printing of the company logo using colored ink is available. Products made from PVC, LDPE and HDPE polyethylene, and polypropylene are popular. Buyers order transparent containers, single-layer and multi-layer products. Delivery - Moscow and Moscow region, regions, for export.

Manufacturers are interested in cooperation with dealers and material suppliers. The size and color of the product is your choice. Address, phone number, website are indicated in the “Contacts” tab. We will send the order on time. To buy packaging bags in bulk, download the price list - write to the manager. Quality at a competitive price!

We will tell you why a business idea for producing plastic bags will not fail, how much money is needed to start a project and how justified is investing in such production.

Most entrepreneurs prefer to start in already developed industries, building a business in the image and likeness of successful analogues. The production of plastic bags is one of these areas.

Do you want to know what investments a new business will require, why it is attractive and unique, and what profit it will bring? Read our article carefully.

How in demand is the production of plastic bags?

The production of packaging materials attracts entrepreneurs with constant demand. Polyethylene has become the most popular packaging method in recent decades, and this trend is not slowing down.

Plastic bags are used in trade, catering, manufacturing, construction, and private households. PET is used to produce bags for garbage, bread, clothing, freezing, sandwiches, cling film, etc. And bright plastic bags with logos are an excellent advertising medium, inexpensive and effective.

We often hear about the need to replace plastic with paper, etc. There is a trend towards this, but the market situation in Russia dictates its own laws. Therefore, you should not be surprised by the opening of another PET production facility: the population and entrepreneurs are choosing budget products.

Why won't such a business idea fail?

So, the first factor in the attractiveness of film packaging is the constant demand of consumers.

The second factor is the wide range. A full-cycle PET plant will satisfy the needs of cities and villages, trade, construction, and manufacturing companies, and respond to seasonal changes in demand.

For example, during the summer season, covering material (films for greenhouses) is in demand, and when harvesting, thick bags are needed for storing and transporting vegetables, etc.

How else does a PET mini-plant attract entrepreneurs, and where do the risks await them?

Let's consider the pros and cons of the project:

Strategy: mini-shop or full cycle?

Is it possible to build a profitable enterprise with minimal start-up capital?

To answer this question, let's conduct a brief comparative analysis:

The table shows the average parameters. Setting up a full-cycle workshop will require 10 times more money and effort than launching a mini-line. But these costs will pay off faster: the cost of production is twice as high, the range is wider.

The first option (for example, a mini-workshop for the production of garbage bags) will become a profitable business if three conditions are met:

1. A profitable contract for the sale of products has been concluded.
2. An agreement was signed for high-quality raw materials at a low price.
3. Costs for delivery and maintenance of the workshop are minimal.

At the same time, the second option, based on the complete processing of raw materials into film and then into bags, may not bring the expected income, but losses. The reason will be the wholesaler’s refusal to cooperate, increased prices for raw materials or other commercial risk.

Having invested a large sum in development, you need to be prepared for both high profits and large losses. The result of any undertaking depends on the specific conditions of doing business, agreements with partners, the market situation and the managerial competence of the owner.

Watch the workshop in action in video format:

Where to start making plastic bags - step-by-step instructions for a businessman

Before making any investment, conduct market research and create a business plan. These actions are necessary, regardless of the chosen production format.

Of course, you can spend money by ordering marketing research from specialists. But if your plans do not include setting up an international holding company for the production of T-shirt bags, and your interests are limited to selling packaging for the needs of the nearby Villa-Kukuevo farms and retail outlets on the Rublevo-Figasevo highway, conduct your own marketing.

Let's look at the parameters that are definitely worth studying.

Consumers. Think about who your customers will be, what products they will purchase and in what quantities. Take into account seasonal demand (if you plan to cooperate with construction companies and agriculture). Also evaluate the distance of customers from your warehouse (price and delivery times matter!).

Advice: take advantage of personal connections and conduct research in the business environment, find out about the needs of different companies for film or bags, volumes, prices, competitors, etc.

Competitors. Analyze who supplies products to your region, whether there are local manufacturers. Evaluate the quality of their product, cost, delivery conditions.

Raw material suppliers. Determine the conditions under which you will receive raw materials for your workshop. Evaluate the cost, delivery time, payment procedure, manufacturer's guarantees, batch sizes and everything that you consider important for your specific business.

Advice: compare several offers and identify two or three suppliers with the most favorable conditions for you.

Business infrastructure. At this stage, determine where your business will be located and who will serve it. Economical options are good if other processes are not affected.

For example, if you choose cheap rental premises 120 km from consumers and the railway station, you risk ruining your business. Transportation costs for transporting containers with PET granules and delivering finished products to the Rublevo-Figasevo highway will become the main cost item; there will be no money for other expenses.

The number of personnel depends on the business model, its volume and strategy. Assess the labor market in your region, the level of average salaries, predict the wage fund of your enterprise.

Study labor legislation, think about how you will formalize relations with employees, how much taxes to pay.

Having gone through this simple path, you need to draw up a business plan.

Step 1. Draw up a business plan

If you intend to apply to a bank for a loan for equipment, a business plan will be required. Those who rely on their own capital should also not neglect planning. Make a simple forecast, taking into account market research data and technological process features.

1. Sales prospects. Based on the planned capacity of the equipment, evaluate the real sales prospects. For example, with a line capacity of 5,000 plastic bags per hour, you can produce 880,000 units in a month. How many of them will you sell in the first month of work and subsequent months?
2. Prices and terms of settlements with clients. Large wholesalers will want individual conditions: low prices, deferred payment. Reflect this in your forecasts.
3. Terms of supply of raw materials. Get ready to buy raw materials on an advance payment basis. You can change the terms and receive discounts and deferments by becoming a regular customer of a large supplier. In your business plan, take into account the costs of stocking raw materials, delivery and storage.
4. Business processes and production maintenance costs. Determine how all departments of your enterprise will operate and how much expenses will be required to maintain it.

As a result of all the calculations, you will get a forecast of production income and expenses for the near future.

For beginners, there is a simple way: download a ready-made business plan for free and modify it taking into account your parameters, obtaining a realistic forecast.

An example of a business plan with calculations of income and expenses for two years.

Step 2. Register a business

At this stage, you need to determine the form of ownership: LLC or individual entrepreneur. The last option is preferred by most entrepreneurs working in the field of small and medium-sized businesses. This is explained by the simple registration and reporting process: the entrepreneur submits an annual income tax return.

Important! When registering, you need to select OKVED activity codes. 25.22 and 51.47 are suitable (production of plastic products for packaging; wholesale trade of non-food products).

It will take from one to three weeks to register your business, depending on the chosen form.

Step 3. Choose a room

When searching for premises, use the following parameters:

1. Ceiling area and height. For a mini-line, a room with a standard ceiling height and an area of ​​10 m2 is sufficient. The full cycle will require special conditions: the room must have high ceilings, have a certain temperature regime for the operation of the automation and extruder (PET granules are melted in it).
2. The area of ​​the premises must be sufficient for storing raw materials and finished products, accommodating personnel (locker room, office, pantry, etc.)
3. Ventilation and communications. PET production is an unsafe process for health, so the room must have a good ventilation system. Check the quality of other communications: electrical wiring, water supply and sewerage systems, heating.
4. Driveways. It is important to have a ramp or area for loading and unloading operations.
5. Infrastructure and location. Ideally, your enterprise should be located in close proximity to consumers and suppliers of raw materials. But miracles do not happen, so look for a compromise, evaluating offers not only by the amount of rent, but also by the convenience for doing business.

Step 4. Selecting personnel

The number of personnel depends on the scale and specifics of the work. To service one line when working in one shift, two workers and a foreman with the functions of a service technician are enough. In addition to the main personnel, a sales department manager, a delivery driver, and a storekeeper may be required. Perhaps all these functions will be performed by the entrepreneur himself.

At this stage, it is necessary to establish relationships with employees by concluding contracts and defining working conditions.

Step 5. We purchase raw materials and equipment

When choosing equipment, get advice from salespeople - dealers of major line manufacturers. Determine the required composition of your line (extruder, die-cutting machine, bag line, flexo printing, etc.). It is not necessary to immediately purchase a complete set: designs for bags can be ordered externally, saving on the purchase of expensive flexo printing.

Plan the timing at this stage, taking into account the delivery, assembly and commissioning of equipment.

When purchasing raw materials, do not forget to obtain certificates of compliance with GOSTs:

• high pressure polyethylene film, for food products GOST 16337-77 (LDPE);
• low pressure film, for bulk dry products GOST 16338-85 (HDPE).

Don’t forget about furniture and production equipment - tables and chairs, cabinets for documents and clothes, a safe, office equipment.

Step 6. Launch the business and begin sales

After registering the enterprise, technical launch of the equipment and training of personnel, proceed to production. By the time you open, you should already have contracts for the supply of finished products.

What you need to properly register a business

In addition to registering an enterprise (LLC or individual entrepreneur), you must obtain permission from the local administration. Opening a PET workshop will require permits from the SES, fire department, energy supervision, and environmentalists.

You can receive a certificate of compliance of finished products with the GOST standard after the start by submitting samples for examination.

How much money will you need to start a business?

Answering the question of how much money is needed to start, here are some simple calculations:

This is an incomplete list of all costs; there are no taxes, marketing costs, transportation, etc.

The amount of starting capital is determined taking into account specific circumstances. For example, the landlord will want an advance payment for the premises for six months, and the supplier of raw materials will ship a year's supply of pellets.

How profitable is such a business?

The production of PET products is considered a highly profitable business. But how do mathematical calculations correspond to reality?

Using the data from the previous example, we will calculate the payback of the workshop, subject to the production of one product - packaging bags:

Calculations show that the investment will pay off in 18 months. In a real situation, profit will depend on many nuances. For example, assortment and sales price, prices for raw materials and rent, etc. It is impossible to foresee all moments, but it is necessary to plan for force majeure.

Therefore, when drawing up your business plan, take into account possible downtime due to equipment breakdown, dumping of competitors' prices, increased utility costs, etc. That is, plan your income to the minimum and expenses to the maximum - this approach will give a realistic picture.

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Our company produces plastic bags with a high-quality logo, which are an attribute of corporate identity and are used by enterprises to promote a new brand.

- a high-tech process that is performed on modern equipment using high-quality primary raw materials and consumables.

• Printing Methods: (Silkscreen printing) circulation from 100 pieces
  - drawing a picture using stencils.
• The persistent dye at the locations of the printing elements penetrates into the printed material. Using silk-screen printing, large images can be printed with sufficient brightness. When making bags, a minimum of time is spent on this process.(Flexography) circulations from 3000 pieces
  - rotary printing based on liquid quick-drying inks using elastic printing forms mounted on cylinders with different circumferences.

The process is quick, inexpensive and allows you to get a high-quality, very bright and durable logo. Profitable for circulation over 3000 copies

In the process of making bags, high, medium and low pressure polyethylene is used. Before printing, the product is exposed to electric current. After this procedure, the logo remains in its original form for as long as possible. The production of bags of various types is carried out using equipment of a certain model.

Bag making process First stage
making bags “Extrusion” is the process of converting granulated polyethylene into film.

Raw materials enter the production workshop in granules. The granules pass through the molding holes of the extrusion equipment, causing them to melt. The melted granules are sent for molding. During the molding process, the amorphous hot mass turns into a film, which cools, hardens, and then is wound into rolls. Second phase
- drawing a picture on the film.

Flexographic printing is applied to polyethylene, which is characterized by high productivity. In recent years, flexography has been widely used to apply designs to the film of future bags and packaging material. At the second stage of bag production, a special dyeing and printing machine is used. Third stage
Rolls of film with a finished pattern are cut into bags using special cutting machines. For the manufacture of various types of products, various models of high-tech devices are used, which also perform cutting and strengthening of handles. Automated machines are able to recognize cuts and welds, count and package finished products.

When making bags with a logo, products of various shapes are obtained, with different methods of attaching the handle.

Our company produces plastic bags:

• "T-shirt" type;
• high pressure with cutting handle;
• medium pressure with cutting handle;
• low pressure with cut-out handle.

Bags made from high-density polyethylene have an attractive appearance. They will not tear, even if there is an object with sharp edges inside. On finished LDPE products with a cut-out handle, the logo is applied using silk-screen printing. HDPE bags (matte and rustling) can withstand very heavy weight. They can accommodate bulky items. PSD products are characterized by high density. The design and size of products, the composition of raw materials and the method of applying the logo are selected based on technological capabilities, customer wishes, timing and circulation.

Make an order

The Klim Plast company specializes in the production of plastic bags. We offer to buy serial products and carry out individual orders. You can get acquainted with the prices for services for the production of plastic bags directly on the website (by downloading the price list). If you have additional questions, please contact the manager by phone.

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Features of the production of plastic bags |

When manufacturing products, special attention is paid to such a parameter as density. Its standard value is 50 microns. At the same time, plastic bags with a density in the range of 50...100 microns can be produced to order. This characteristic is directly related to the strength of the finished product and its wear resistance. Denser products withstand severe mechanical tensile loads, while reducing the likelihood of tearing or damage to the material.

In the manufacture of plastic bags, low, medium or high pressure polyethylene is used:

When manufacturing plastic bags, the size and design of products, the composition of raw materials and the method of applying the logo are determined based on:

technological capabilities

• customer requirements

It is worth noting that this product is intended for repeated use.

We also produce a separate class of packaging products – plastic bags with a lock. They are great for packing clothes, packaging small items and storing documentation. High tightness guarantees the safety of objects placed in them.

Cost of making bags

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Advantages of making custom plastic bags |

Recognizability of a company logo or product brand is one of the foundations of modern marketing. Using branded, memorable packages is inexpensive and effective advertising. Packaging materials with the company logo will attract the attention of potential consumers at conferences, seminars, and exhibitions. Custom made plastic bags are often used in company stores.

• First of all, our products will be of interest to:
• owners of stores (including chain stores) of clothing, food, electronics, household chemicals, building materials and other popular goods;
• representatives of medium and large businesses who want to increase brand awareness;
• advertising agencies and enterprises specializing in organizing festive and public events, exhibitions, conferences, etc.

representatives of the light and food industries and many others.

By ordering the production of plastic bags, you will not only help promote your products, but will also delight regular and new customers. Choose high-quality and memorable packaging materials!

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Equipment for the production of plastic bags |

The production of such products is a high-tech process. The most modern equipment is used to organize it. The full cycle production line for plastic bags includes the following equipment:

extruders designed for processing raw material granules into film;

multifunctional bag making machine, with integrated punching press, photosensor, servo drive, thermal needles, conveyor. It allows the production of plastic bags of various modifications;

film cutting device and additional equipment.

To ensure that our products meet strict standards, we use modern technology and high-quality raw materials. Manufactured products undergo control at all stages of production. They fully comply with sanitary rules and GOST R 50962-96.

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Plastic bag production process |

It is possible to produce plastic bags of different shapes, with different ways of attaching the handle. The cost of production depends on: film density, type and supplier of raw materials, packaging size, presence/absence of handles, volume and complexity of color printing. Other features, such as non-standard shape, are also of great importance.

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Benefits of cooperation |