Plastic Bag Manufacturing: How Plastic Sacks Are Made

How are plastic sacks made? There is no simple answer: the process depends on the type of product and, above all, on whether the sack is made from virgin or recycled material. Most of our sacks are made from HDPE, while demand for compostable raw materials keeps growing.

The plastic bag manufacturing process

The process starts with melting plastic pellets; the molten mass then moves on to the extrusion department, where the film for the plastic sacks is formed. The mixed material is fed into extruders, where it is heated to a specific temperature and blended. The molten plastic can be blown out of the extruder into the shape of a bubble. The bubble is blown vertically to a great height, which allows the film to be properly positioned and cooled. As the final step of extrusion, the bubble is passed through a series of rollers to flatten it and then wound onto large cores, producing a film roll weighing several hundred kilograms.

The film roll then reaches the area where the film is converted into sacks, and is placed in the unwinder. Once the film is running on the unwinder, it is treated with an electrostatic discharge. This prepares the film properly for printing, where the sacks are given the various marks and logos our customers require.

After printing, the large film roll is cut to size with hot knives. One side of the sacks is sealed, and the film is then fed into the bag-making machines, where the final shape is formed. All internal waste is fed back into production, so there is practically no production loss.

We take a slightly different approach for plastic sacks made from recycled materials. Plastic from separate waste collection must first be cleaned of contaminants: it is washed and then processed into pellets, which are used to make brand-new sacks – of the same quality as sacks made from virgin raw materials – using the process described above.

Custom plastic sacks

As a manufacturer, we have cut out the middleman, so you deal with us directly – which means you get quality products at factory prices. Our production capacity allows us to make products tailored specifically to your needs, with your own design, logo or lettering.

To do this, you need to consider the following:

Virgin or recycled raw material – recycled material is cheaper but may contain contaminants

Sack size – specified in litres or centimetres

Type – drawstring or standard design

Strength – this is determined by the film thickness

The larger the sack, the thicker it is worth ordering, since a filled sack has to carry more weight without tearing. If you cannot decide, request a sample or a consultation!

As an environmentally conscious company, we use 65% recycled raw materials in production, recycle production waste in-house and support initiatives that promote environmental protection and environmental awareness.