Flexible intermediate bulk containers (FIBCs), also referred to as bulk bags, are essential for handling, storing, and transporting bulk items in the industrial packaging sector. Bulk bags must provide structural integrity, safety, and dependability for everything from agricultural produce and food-grade items to heavy mineral concentrates and dry chemicals.
A strategic alliance with our sister company, Integrated Polypropylene Products (IPP), a member of the Custom Extrusion (CE) family, drives Custom Bulk Bags‘ (CBB’s) smooth manufacturing capability.
To understand how premium bulk bags are made, it’s necessary to examine the unique upstream and downstream processes of IPP and CBB, as well as how their collaboration promotes manufacturing excellence.
IPP: Upstream weaving and extrusion
IPP is the expert in upstream polymer processing and weaving. IPP’s main goal is to transform basic polymer resins into the high-strength materials needed to build heavy-duty FIBCs. IPP creates high-tenacity flat tapes by melting premium virgin polypropylene (PP) resin and extruding it. To make the fabric resistant to solar deterioration in harsh African environments, ultraviolet (UV) stabilisers are added during extrusion.
IPP weaves the extruded PP tapes into strong, high-GSM fabric rolls that can sustain high external pressures using high-speed circular looms. Heavy-duty lifting loops and structural straps that are necessary for cranes and forklift rigs to handle safely are also woven by IPP. When moisture resistance or dust containment is needed, commission lamination is used by coating the woven fabric with PP or LDPE.
CBB: Downstream assembly and customisation
CBB serves as the manufacturing, design, and downstream conversion expert. CBB converts IPP’s woven rolls and components into customised, functional bulk bags. Specialised high-strength threads are used to stitch together fabric panels that have been cut to precise pattern standards. CBB inserts polyethylene (PE) and aluminium foil barrier liners or uses specific filler cords to suit triple sift-proof seams for fine powders or hazardous chemicals.
Custom fill tops, discharge spouts, iris valves, and loop configurations can be designed to fit client hoppers and automated conveyor systems. To guarantee complete compliance with ISO 9001:2015, ISO 21898, and UN dangerous goods requirements, CBB tests completed units for tear resistance, drop impact, stacking stability, and top-lift stress.
The Custom Extrusion ecosystem
As part of Deneb Investments Limited’s ownership structure, CBB and IPP work together under the Custom Extrusion (CE) brand. Under a single corporate roof, this full vertical integration connects raw resin extrusion to final bag sewing. CE removes the need for imported fabrics, reduces production lead times, and protects customers from fluctuations in exchange rates and international freight by managing the whole supply chain internally.
Every stage of FIBC creation is handled by our cutting-edge production facilities in Durban under strict quality control procedures. The manufacturing procedure consists of the following steps:
- Extrusion of raw material – UV stabilisers are mixed with virgin polypropylene resin and then extruded into flat tapes.
- Extrusion coating – To increase abrasion and moisture resistance, protective PP or LDPE coatings are laminated onto the fabric.
- Precision weaving – Tapes are woven into heavy-duty lifting webbing and high-GSM circular fabric rolls.
- Automated cutting – Rolls of fabric are precisely cut into bottom spouts, top inlets, and body panels.
- Stitching and liner integration – Expert artisans use stronger seams to sew the panels, adding inside liners or dust-proof cables as necessary.
- Custom printing – Batch codes, safety warnings, and corporate logos are added to woven panels using high-clarity flexographic printing presses.
- Mechanical testing and inspection – Prior to final packing, sample units are subjected to tensile testing, fabric burst testing, seam pull checks, and top-lift stress testing.
Custom Extrusion: Level-1 B-BBEE supplier benefits
Under Deneb Investments Limited, Custom Extrusion is a Level-1 B-BBEE accredited supplier in South Africa. For local clients, working with a Level-1 B-BBEE manufacturer provides substantial strategic advantages:
- 135% procurement recognition – Clients can increase their preference procurement scores by claiming 135% of their procurement spend against their own B-BBEE scorecards when they purchase FIBCs from a Level-1 supplier.
- Significant local capacity – We provide assured supply continuity for significant mining, chemical, and agricultural industries with an annual output of up to 3.5 million bulk bags supporting Safe Working Loads (SWL) from 500 kg to 2000 kg.
- Encouraging local transformation – Purchasing locally produced bulk bags from Durban promotes economic empowerment, protects manufacturing employment, and propels South African industrialisation.
Custom Extrusion offers South African industry robust, locally produced packaging solutions that are suited to demanding operating needs by combining the technological prowess of CBB and IPP. To discuss the details of your bulk bag, please contact our experts today.
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Custom Bulk Bags is a major South African manufacturer of woven polypropylene bags for various industries, including mining, chemicals and agriculture. We are a Level 1 B-BBEE supplier that falls under the ownership structure of Deneb Investments Limited. For more information on our products, contact sales@custombulkbags.co.za.
