An Overview of NZ Accessories Ltd.

Inspired by: Authored by:

Md. Mahabur Rahman Md. Rasel Mahmud
Deputy General Manager Trainee Executive-Planning
NZ Accessories Ltd. NZ Accessories Ltd.

Supervised by: Assisted by:

Md. Farhan-Ul-Wassy Sarkar Abdullah Zahid
Deputy Manager Executive-Product Development
NZ Accessories Ltd. NZ Accessories Ltd.
Functions of Garments Accessories:
Accessories play a vital role in garment manufacturing. Accessories are used to serve different
functions of a garment. Some of the functions are given below:

1. Garments accessories sometimes act as a decorative material.

2. Accessories can make a garment more suitable to wear.
3. Accessories are used to make the garments more flexible.
4. Accessories help to ensure the garments durability.
5. To fulfill customer demand different accessories are used.

Normally garment accessories can be classified in three ways:

A. Basic accessories
B. Decorative accessories
C. Finishing accessories

A. List of Basic Garment Accessories:

1. Thread
2. Zipper
3. Interlining
4. Button for example: Snap button, Plastic button, Metal button.
5. Label: Main label, Size Label, Wash care label
6. Motif: Leather, Plastic, batch Metal
7. Pocketing fabric
8. Lining
9. Velcro
10. Elastic
11. Cord
12. Ribbon
13. Toggles
14. Rivet
15. Collar bone.

List of Decorative Accessories:

1. Elastic tape
2. Buttonhole tape
3. Piping
4. Moiré ribbon
5. Seaming tape
6. Welted tape
7. Ribbed tape
8. Velvet ribbon
9. Bias binding
10. Stamped tape
 11. Taffeta ribbon
12. Galloon
13. Fringes
14. Cords
15. Tassels
16. Rosettes
17. Soutache
18. Pompons

C. List of Finishing Accessories:

There are some finishing accessories:

1. Hang tag
2. Price tag
3. Plastic/ poly bag
4. Tissue paper
5. Carton
6. Scotch tape
7. PP belt
8. Tag pin
9. Plastic clip
10. Stiker
11. Butterfly
12. Collar insert
13. Back board
14. Necks insert
Sewing Thread
 Chapter 1: Twill Tape Section

Introduction:
Twill Tape section is one of the most vital section in the company that plays a
significant role to company’s growth by ensuring highest product quality of
product such as twill tape, round draw cord, tube draw cord etc. The section
consists of 23 operator, 1 quality control and 2 incharge to operate and supervise
the whole production system. Drawcord is a multipurpose cord that may be used to
do everything from fasten bags and shoes to alter the fit of waistbands and
sweatshirts. Elastic drawstring cord, nylon drawstring cord, polyester drawstring
cord and cotton drawstring cord are just some of the options out there. Shoulder
tape may provide muscle and joint support and improve range of motion. It might
also help reduce pain and inflammation. A physiotherapist may be able to advise a
person on the best application and configuration of KT to help relieve pain for
specific shoulder issues.

Product Produced in Twill Tape section:

 Fig. Product produced in Twill Tape section

Twill Tape Process Flow Chart

Tube Drawcord Process Flow Chart

Round Drawcord Process Flow Chart
Production Per KG
 100% Cotton

Item Size(cm) yds/kg

0.8 115
RDC
0.7 120
0.7 250
1 190
TDC
1.2 180
1.5 90
0.5 500
1 250
TT
1.5 200
1.2 220
Grossgain 1 300

100% Polyester

Item Size(cm) yds/kg

0.8 130
RDC
0.7 140
0.7 250
1 200
TDC
1.2 190
1.5 150

Capacity

Tube Drawcord

Machine Total Capacit

Manufacturer Capacity/day(yds)
Name machine y
48/2 Shanghai & Xiangdao+Zunxin Delicate 2000 10 20000
48/1 Shanghai & Xiangdao+Zunxin Delicate 950 7 6650
Total 26650

Round Drawcord

Machine Total
Manufacturer Capacity/day(yds) Capacity
Name machine
 16/4 Shanghai & Xiangdao+Zunxin Delicate 5000 12 60000
8/8 Shanghai & Xiangdao+Zunxin Delicate 2000 2 4000
Total 64000

Twill Tape

Hea Capacit
Machine Name Manufacturer Capacity/day(yds) Total machine
d y
Twill Tape 12 YK+KY 15840 1 15840
Twill Tape 10 YK+KY 14300 1 14300
Twill Tape 8 YK+KY 11440 1 11440
Twill Tape 6 YK+KY 7260 1 7260
Twill Tape 6 YK+KY 5280 1 5280
Total 54120

Intermingling
The process of creating tangle knots in synthetic yarn using heating
pressure. Intermingling is a technology which is very economical than the older
technologies like sizing, twisting in synthetic yarn weaving. In this technology air
causes the filaments will be intertwined and mingled with each other to form a
compact section. Intermingling finds applications in while spinning stage, at
drawing stage and also at warping. Intermingling jet parameters, Machine
parameters, Feed yarn properties affects intermingling process. The performance of
intermingling process is generally evaluated on the basis of nip frequency, nip
stability and nip uniformity.

Yarn types

NIM (non-intermingled), SIM (semi-intermingled), and HIM (high-intermingled)

are the three main types of intermingled yarn.

Physical properties
The level of intermingling between the filaments determines the physical
properties of the yarn.
  Applications
SIM yarn is used in a variety of textile applications because it offers a balance
between bulkiness and strength.

Comparison to other types of yarn

NIM: Non-intermingled yarn has no knots, or 0–10 knots per meter.

HIM: High-intermingled yarn has a high level of interlacing, or 100–120 knots per
meter.

LIM/SIM: Low intermingled yarn has relatively low entanglement spacing and
tenacity. 40-50 knots

Yarn Count of Spun Polyester Yarn

26s means that yarn has 26 meters of yarn per gram.

28s means that yarn has 28 meters of yarn per gram.

24s means that yarn has 24 meters of yarn per gram.

30s means that yarn has 30 meters of yarn per gram.

32s means that yarn has 32 meters of yarn per gram.

Cotton Count
Cotton Count is defined as the number of 840 yards length of yarns in one pound.
It means that the number of yarns of 840 yards length required weighing one
pound. For example, a 30 count yarn means you need 30 yarns of 840 yards length
to make it one pound weight.

In cotton count (indirect yarn numbering) system, higher the count of yarn is finer
the yarn. For example, a 40’s yarn is two times finer than a 20’s yarn.
Yarn Count: Yarn count is a number which indicates the mass per unit length or
the length per unit mass of the yarn.

Indirect yarn count system or numbering system

There two types of yarn count system. They are as follows.

1. Direct Count System

2. Indirect Count System

Direct Count System

The direct count is determined by the weight of a fixed length of yarn.

The weight per unit length is the count (direct count). The common
features of all direct yarn count systems are the length of yarn is fixed
and the weight of yarn varies according to its fineness.

We should remember in direct yarn count system

 In direct count system Length is fixed.

 Higher the yarn number coarser the yarn and
 Lower yarn number finer the yarn.

The following formula is used to calculate the direct yarn count

N = (W × l)/L
Here,

N = Yarn count or numbering system

W = Weight of the sample

L = Length of the sample

l = Unit of the length of the sample.

Some direct yarn count system

Tex system: Number of grams per 1000 meters.

Denier: Number of grams per 9000 meters.

Decitex: Number of grams per 10,000 meters

Militex: Number of milligrams per 1000 meters

Kilotex: Number of kilograms per 1000 meters

Jute count: No. of pound (lb) per 14,400 yards

What does 35 Tex define?

35 Tex means 1000 meters of yarn weighs 35 grams. If 1000 meter long yarn
gives 35-gram weight then it is called 35 Tex.

Indirect count (length/weight)

The length of a fixed weight of yarn is measured. The length per unit weight is the yarn indirect
count. General features of all indirect count systems are the weight of yarn is fixed and the length
of yarn varies according to its fitness.

Points should remember during the indirect count

 In indirect count system weight is fixed.
 Higher the yarn number finer the yarn and
 Lower yarn number coarser the yarn.
 The following formula is used to calculate the indirect yarn count

N = Yarn count or numbering system

W= Weight of the sample

L = Length of the sample

l = Unit of the length of the sample

w =The unit of weight

Some indirect yarn count system

 English count system, Ne: No of 840yd lengths per pound
 Metric count, Nm: No. of kilometers per kilograms
 Woolen count (YSW): No. of 256 yd lengths per pound (lb)
 Woolen count (Dewsbury): No. of yd lengths per oz
 Worsted count, Nek: No. of 560 yd lengths per pound
 Linen count, NeL: No. of 300 yd lengths per pound

yarn weaving process

 Machine and manpower

Available Operator
Machine/Operation Shift
operator Name
Anwar A-Shift
Warping Machine 1+1
Jewel B-Shift
Md. Rabiul A-Shift
Bobbin Machine 1+1
Md. Selim B-Shift
Najrul A-Shift
Monjurul A-Shift
Round Drawcord 2+2
Zahirul B-Shift
Sumon B-Shift
Taybur A-Shift
Rahem A-Shift
Rayhan A-Shift
Rashed A-Shift
Tube Drawcord 4+4
Alim B-Shift
Akash B-Shift
Afjal B-Shift
Amran B-Shift
Shafiqul A-Shift
Razzak A-Shift
Mamun A-Shift
Twill tape 3+3
Abu Sayed B-Shift
Rasel B-Shift
Ali Akbar B-Shift
Tipping 1 Tushar B-Shift
Quality Control 1 Zillur B-Shift
Incharge 1 Shah Alam A-Shift
Assistant Incharge 1 Rezaul A-Shift
Batch 2+2 Carton A-B
Helper 1 Fahim
 Label Section
What are woven labels?

Woven labels are typically made up of cotton or polyester, with the threads woven together to
create both your design and your label. This allows the entire label to have a soft finish and
increases its durability. Due to the nature of woven labels, they can enhance the look and feel of
your brand in a way that printed labels may not be able to. Woven cotton exudes a luxury feel
that is often chosen by leading luxury brands like Gucci, YSL and many more

What are printed labels?

Printed labels are usually made from satin, cotton or poly-blends. Your logo or choice of
imagery is digitally printed directly onto the label, meaning that you have an endless choice of
colour and design options. This makes printed labels a great way to showcase who you are as a
company and improve brand recall.

Various Types of Labels Used in Garments:

1. Main label: The main label is a style of clothing label that adds the brand logo and name to the
fabric via weaving, printing, heat transfer, or a leather method. Often, it is at the inner and rear
center seam of the bottom or beneath the inner and back collar of the top. In general, while
utilizing labels, a garment must have the primary label.
2. Care label:
Care labels are garment wash labels and care symbols that identify the fabric type, clothing care
instructions, and the proper washing technique. We sew the emblems onto textiles or garments.
Like cleaning, drying, ironing, and washing garments. Typically, businesses or brands will manage
washing instructions and print the company’s logo, and the size on this kind of labels.

3. Size label:
Clothing with a size label has that size printed or woven into the label. Sizes S, M, L, and XL for
clothing, beds, shoes, and bags, for example. Print size labels and woven size labels are both
examples of size labels. They also employ hot-cutting or laser cutting. Its components include
satin, nylon, polyester and cotton, among others. When people are shopping, the first thing they
do is check the size of the clothing to determine whether or not it matches them.
4. Heat transfer label:
Heat press the logo or design onto specialized transfer paper, synthetic film, or plastic film to
create heat transfer labels, which are used as clothing’s primary labels. Apply them to the
materials of the clothing after peeling off the film. As a result, we can also refer to them as
thermal transfer labels or tag-less tags. Naturally, it is ideal for t-shirts.

5. Metal label:
Metal labels are tags and accessories made of metal that can have brand logos engraved on
them for use with garments, headgear, or bags. There are many different kinds of metal labels,
including aluminium, stainless steel, silver, copper, brass, and zinc alloy labels. Then, metal
labels are widely used and are produced using techniques including stamping, printing, and laser
cutting.
 6. Manufacturer label:
This label contains the manufacturer’s code that customers have provided. The majority of
global purchasers source clothing from various regions of the world and sell it all over the world.
If a customer needs to find out who made a specific product, they utilize this code.

7. Composition label:
The composition label provides information about the fabrication and percentage of any clothes’
makeup. In other words, it specifies the fabrication (e.g., Cotton Sub denim, Cotton Regular
denim, etc.) and composition percentage (e.g., 95% Cotton, 5% Spandex, 100% Cotton, etc.)
used in its production.
 7. Flag label:
A flag label is a very small label that displays the buyer’s brand name or emblem. It is fastened
to the side seam of the clothing’s bottom pieces

8. Barcode label
9. Traceablity Labels

Types of ribbon

1. Satin
2. Paper
3. Taffeta
4. Cotton
5. Mat

Satin Ribbon:

A. One sided
B. Both Sided
C. Both Woven

Taffeta:

1. Tear able
2. Non Tear able
 Woven Label Cut & Fold Options

End Fold

Label is folded down on the left and right side. This option is most suitable for sewing in neck
labels.

Mitre Fold

The ends are folded under and up, creating a tab to be sewn into the seam.
Manhattan Fold

Label is folded at top and centre.

Centre Fold

Label is folded in the middle and usually sewn into a seam.

Straight Cut

Label is cut and edges are heat sealed

Costing:

Printing Capacity
M/C Specification Color Capacity(m)
Machine 1 Nylo Printing Machine Upto 6 30000
Machine 2 Flexo Printing Machine Upto 3 20000
Machine 3 Flexo Printing Machine Upto 3 20000
Machine 4 Flexo Printing Machine Upto 4 25000
95000

Cutting Capacity

Length Capacity(m
M/C Specification
)
Machine 1 Cut and fold Upto 200 25000
Machine 2 Ultrasonic Cutting Upto 200 20000
Machine 3 Ultrasonic Cutting Upto 200 20000
65000
Types of Label Printing Technologies: A Detailed Exploration

Flexography

Feature Detail
Print Type Flexography
Print Speed High (Varies based on specific job requirements)
High-volume runs, continuous patterns, packaging,
Best Used For
labels
Print Quality High, suitable for fine detail
Material Compatibility Wide range, including paper, plastic, metallic films
Ink Type Fast-drying, ideal for various substrates

This technique is compatible with a wide array of substrates. It employs flexible photopolymer plates
wrapped around rotating cylinders on a web press. These plates receive a fast-drying, low-viscosity ink
that is then transferred to the printing surface, making flexography exceptionally suitable for packaging,
labels, and wallpaper.

Digital Printing

Digital printing marks a transformative approach in label production, characterized by its

unparalleled flexibility and immediacy, particularly suited for short to medium runs. This method
eliminates the need for physical plates and extensive setup, enabling direct image transfer from
digital files to the printer.

Digital printing encompasses several technologies, including.

 Inkjet Printing
 Laser Printing
 Thermal Printing
Inkjet printing is a key element of digital printing technology, celebrated for its precision and
versatility. This method propels microscopic droplets of ink directly onto the substrate,
producing vibrant, high-resolution images with a wide color palette.

Ideal for detailed graphics and color-intensive labels, inkjet printers can handle a variety of
materials, such as paper, plastic, canvas, and some metals. This flexibility makes them suitable
for a diverse range of applications, enabling them to meet the demands of various industries.

Laser printing is highly regarded for its precision and rapid processing within digital printing. It
employs a sophisticated electro-photographic technique that uses a laser beam to precisely
outline an image on a photosensitive drum.

The areas of the drum touched by the laser become electrically charged, attracting toner—a
finely ground powder. This toner is then transferred onto the printing surface, which can be
paper or plastic, effectively replicating the image.

The final stage of the process involves applying heat and pressure, which binds the toner to the
surface, producing crisp and durable prints. This method is favorable for delivering sharp text
and detailed images quickly and efficiently.

Thermal printing produces a printed image by selectively heating coated thermo-chromic

paper, commonly known as thermal paper, as it passes over the thermal print head. The coating
turns black in the areas where it is heated, producing an image. This method allows for quickly
and efficiently creating high-quality printed images and text.

The process is straightforward and swift, involving minimal moving parts, reducing mechanical
failure risk. Thermal printers are compact, easy to use, and require little maintenance, making
them ideal for applications that require fast, reliable output, such as ticketing, labeling, and
receipts.

The efficiency and reliability of thermal printing have made it a widespread choice in various
industries that value speed and quality in their printing needs.

Different tools:

1. Ribbon
2. Ink
3. Block
4. Cylinder
5. Plate Mounting Tape

PERFECTOS® provides a range of ready to use FABROFLEX® flexographic printing inks

that can be used to produce wide width, high quality photographic printed fabric labels
particularly suitable for bedding and mattresses in addition to apparel, sportswear, healthcare,
work-wear and promotional items.
FABROFLEX® inks are:

 STANDARD 100 by OEKO-TEX® Product Class I compliant

 Restricted Substance List (RSL) compliant to the World's leading brands
 EU REACH Regulation (EC) No 1907/2006 compliant
 RoHS compliant
 Consumer Product Safety Improvement Act (CPSIA) compliant
 washable up to 95°C
 suitable for printing onto a wide range of substrates
 capable of producing high quality photographic printed fabric labels
 non-hazardous
 formulated to be free from APEO, cadmium, formaldehyde, organotin, phthalates and
PVC
 available as solvent based (SB) inks.

Steps of Label Production:

1. Layout making
2. Block preparation
3. Block separation
4. Engaging block with cylinder
5. Putting cylinder into machine
6. Putting ink
7. Putting ribbon in input and roll in output
8. Start the machine
9. Curing process
10. Cutting process
11. Packaging
Elastic Section
What is Garment Packaging?

Garment packaging is the final process in the production of garments, which prepares the
finished merchandise for delivery to the customer. These operations come under the materials
handling methods and are no less important than other systems used in the factory. After
completing the entire manufacturing task, apparel is required to be packed. After packing, it is
placed in cartons as per instructions and then it is stored in a store section before it is delivered to
the respective buyer.

Packaging refers to the container that carries a product. Two basic objectives of packaging are
preventing any damage to the product during transportation and enhancing the features of the
product to the consumer for a sale of it. Packaging has two major functions:

 Distribution
 Merchandising

The main purpose of distribution packaging is packaging the garment in a way that it allows the
garment manufacturers to transport the garment at a minimum cost and in the shortest time to the
retailer or purchaser, without deteriorating the quality of the product. The merchandising
function deals with showcasing the garment product in a way that it stimulates consumer desire
for purchasing the particular product.

Types of Packaging Forms:

The basic types of packaging forms used in garment and allied products are

 Bags
 Boxes
 Cartons
 Cases
 Crates
 Twine
 Wrappers
Packing garment into poly bags

Traditionally garments are packed into poly bags before placing them into cartons box. Garments
may be packed individually in the poly bags and the ratio will be specified by the buyer.

 − 1. Single piece packing – a single garment is packed into the polybag or into a
cardboard box.
 − 2. Blister Packing: In blister packing, more than one garments are packed into a
polybag in a size and colour ratio. Later those poly bags are packed into a carton box.

• Packing garment without polybag

The other method is that the garments are just folded and arranged in the carton boxes without
putting them in the polybag. When it comes packing multiple of garments into carton boxes
colour and sizes are considered as main criteria for differentiating packing method. Different
ways of packing are as follows:

− 3. Solid Packing: In this method of packing, the carton box will include garments of a single
color and same size. For example, 20 shirts of a similar color say navy blue and the size say S
will be put in one carton box.

Assorted packing or Ratio packing:

 − 4. Ratio Packing: In this method, the carton box includes garments of the same color
but of different sizes according to the ratio. For example, S : M : L : XL = 5 : 7 : 7 : 5.
 − 5. Mixed Packing: In this method the carton box includes garments of different colors
but of same size or garments with different colors and different sizes in a particular ratio
form.
 Poly Section
"Poly production for garments accessories" refers to the manufacturing process of plastic poly
bags, primarily used as packaging material for clothing items, considered a key accessory in the garment
industry; essentially, it means producing plastic bags specifically designed to hold and protect finished
garments during storage and shipping.

Types of polybag:
1. Single piece packing poly – a single garment is packed into the polybag or into a cardboard box.

2. Blister Packing: In blister packing, more than one garments are packed into a polybag in a size and
color ratio. Later those poly bags are packed into a carton box.

3. Gazetted poly bag: It is commercially known as Bopp poly bags or self-adhesive bags. It is like normal
poly bag but there will be a self-adhesive provision and extension at one side of the poly bag.

4. Poly bag with hangers: Is used both in the hanger pack as well as stand-up pack.

Chapter 1: What is a Poly Bag?

A poly bag is a widely used shipping and packaging solution crafted from polymer materials
known for their durability, flexibility, and adaptability. Typically made from polyethylene or
polystyrene, poly bags are engineered to offer a compact, effective means of protecting and
securing products, components, and merchandise.

Chapter 2: How Poly Bags are Made?

The creation of poly bags involves intricate and scientifically designed processes, meticulously
planned to achieve high-quality results. The production starts with plastic resin pellets, which are
used to create the specific type of film and thickness required for the bags.

The choice of resin used in manufacturing poly bags affects their durability, weight, and
thickness. Five primary types of resins are employed in plastic bag production: high-density
polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene
(LLDPE), medium-density polyethylene (MDPE), and polypropylene (PP). The specific
characteristics and properties of these resins are crucial in determining the strength and longevity
of the bags.
Creating high-quality poly bags starts with selecting the appropriate materials for the bags.

Extrusion

After selecting the appropriate resin, it is introduced into the hopper of an extruder. Initially,
plastic pellets were melted by heating them in a vat or barrel, leading to uneven heating where
pellets closer to the heat source became hotter and more pliable.

To address this issue, the extruder was developed—a screw-based mechanism that ensures
uniform heating of the material. Operating at temperatures between 350°F and 450°F, the
extruder melts all pellets to a consistent temperature. The extruder features a screw mechanism
with a hopper at one end and a die at the other. The resin is fed into the hopper, where it
gradually moves into the extruder’s barrel. As the screw turns, the pellets are conveyed along the
barrel, which is heated by units placed along its length.
Inflation

The molten plastic resin exits the extruder die in the form of a tube, which is then inflated and
stretched to achieve the desired size and shape of the poly bag. Air is used to inflate the tube,
creating the necessary thickness of the plastic film. The rate of inflation and the subsequent
cooling process play crucial roles in determining the thickness and properties of the polyethylene
film.

Cooling Tower

Once the plastic tube is fully extended, it remains in the cooling tower until it solidifies. In the
tower, it resembles a tall, vertical balloon of plastic. As the tube ascends, it comes into contact
with the tower walls and cools. This cooling process is crucial, as it significantly influences the
final properties of the polyethylene film.
Nip Rollers

To create the plastic film, the tube passes through a collapsing frame before reaching the nip
rollers, which flatten it into a lay-flat form that is then rolled into large rolls of plastic. Nip rollers
are crucial for providing high traction, controlling web tension, and ensuring smooth winding
onto a roll.
Nip rolling also plays a key role in controlling the thickness of the poly bags. By adjusting the
gap between the rollers and the pressure applied, manufacturers can maintain consistent
thickness throughout the bags.

Rolling Film

After the inflated film is flattened and passes through the collapsing frame and nip rollers, it is
wound into large rolls for further processing. Roll winding machines meticulously wind the
plastic film onto cores or spindles. The size and length of these rolls can vary depending on your
requirements and the capacity of the equipment. From these rolls, the poly bags are printed,
formed, cut to size, and sealed.
Flexographic Printing

Poly bags come in various sizes, thicknesses, colors, and forms. Bags produced for stores, shops,
and retail outlets often feature printed branding and additional information. The printing on poly
bags is accomplished through a process known as flexography, a roll feed web printing method
used for materials such as film, foils, paper, and cardboard.

The image to be printed is first designed using computer software like CAD. A negative of this
design is then placed on a light-sensitive polymer plate, which is exposed to ultraviolet light. The
UV light hardens the image areas on the plate, while the surrounding material turns into a
gummy substance that is washed away, leaving the image on the plate.

This completed plate is wrapped around a cylinder. As the poly material moves between two
cylinders, with one cylinder bearing the plate, the plate is inked and the image is transferred onto
the bags

Cutting

During the printing process, the roll of film from the extruding and blowing stages is unrolled
and fed through the flexographic printer. Once printed, the poly bags are re-rolled in preparation
for the cutting process.
Bottom Seal vs Side Seal

Plastic bags are made by either side sealing or bottom sealing. Side seal bags are slightly cheaper
and are usual for small size bags bottom seal bags are typically larger or for heavy duty
applications.

Side Seal Bags

Side Seal bags are made using center fold film. The bag forming machine simultaneously cuts
and seals the sides of the bag. Handles or air holes can be formed prior to the cutting and sealing
operation, there are a number of variations on the side seal process.

Side sealing is used to make,

 press seal bags

 trade show bags
 small and medium general purpose bags
 bags with bottom gussets.

Side seal bags are not as strong as bottom seal bags but they are cheaper to produce. Side seal
bags are still very strong but they are not suitable for applications such as potting mix, potato
bags etc.
Bottom Seal bags

Bottom Seal bags are made using lay flat tube. The bag forming machine seals the
bag and cuts the bag just below the seal. Handles or air holes can be formed prior
to the cutting and sealing operation. Bottom sealed bags are only stronger than side
seal bags when used for carrying materials that flow, IE grain, flour, sand, pebbles,
asphalt. For a heavy rigid item (eg a small motor) side seall bags are just as strong.

Bottom seal bags are used for heavy duty applications such as.
- Potting mix and pebbles.
- Onions, potatoes and carrots.
- Food bags that require a water-tight seal.
- Bags with side gussets for increased volume.
Layout Example
Chapter One – What is a Corrugated Box?

A corrugated box is a single-use container constructed with multiple layers. It typically consists
of an inner layer, an outer layer, and a middle layer. The middle layer is designed with a fluted or
wave-like structure, which offers cushioning and support for heavier items placed inside the box.
This fluted layer enhances the box’s durability and ability to absorb impacts, making it ideal for
protecting goods during transportation and storage.

Cardboard that is typically found in greetings cards, craft stores, and food packaging usually
refers to heavy paper-pulp or a thick paper stock. This cardboard is easily folded and formed, but
doesn’t offer much product protection. Corrugated cardboard, on the other hand, is formed in
three layers; and inner layer, an outer layer, and zig zagged fluting in between. This makes the
corrugated cardboard more durable, offering a higher level of product protection.
Paper Types: What are the components of corrugated board made of?

Different paper types can be used to form the layers of corrugated board. The paper type used
has an impact on the board’s performance.

All three outer, inner and corrugated liners are most commonly made of either Kraft or Test
paper.

Kraft Paper

Kraft paper is made from softwood trees. As it’s made from virgin material, it is more robust and easier
to print on, making it the most popular option.

Test Paper

Test paper is a double (or duplex) layer of paper made from recycled material, and it’s more commonly
used for the inside liner.
Paper Weights: How is paper weighed, and what is GSM?

Paper is weighed in GSM: grams per square meter.

Common paper weights used for corrugated board are:

• 115/125 GSM
• 140/150 GSM
• 185/200 GSM
• 300 GSM

Flutes: What different flute options are there?

The flute is the corrugated, wavy section between the two flat liners.

Flute Materials

Flutes are usually made from either recycled material (also known as waste-based fluting or WBF) or
semi-chem fluting (SC).

Flute Weight

Like liner paper, fluting is weighed by GSM. Typical weights for fluting are:
• 90 GSM WBF
• 105 GSM WBF – Most common flute standard
• 112 SC and WBF
• 150 SC and WBF
• 175 SC and F

Chapter Two – How Corrugated Boxes are Made?

Corrugated Box Construction

A corrugated box can have one of three wall configurations: single-wall, double-wall, or triple-
wall.

 Single Wall (3-ply)- This is the simplest corrugated wall design, with a single outer layer
and inner layer with fluting between the two layers.
 Double Wall (5-ply)- The double wall design adds an additional layer of fluting to
produce a box capable of handling heavier and larger items.

 Triple Wall (7-ply) - As the name implies, triple wall corrugated boxes have three layers
of flutes. Each layer has differently-sized flutes to add stability. The added layers
maximize cushioning and compression strength.
Corrugated Flutes

Corrugated boxes typically feature one of five standard fluting types: A, B, C, E, and F. While
these are the common types, manufacturers and designers have the flexibility to create custom
fluting profiles. These custom versions can include combinations of the standard types or entirely
unique designs.

 A – is the original type of flute at 36 flutes per foot and is used for double wall applications and
thick corrugated padding.
 B – has the second highest arch size with 49 flutes per foot and has stacking strength and crush
resistance.
 C – most commonly used flute with 41 flutes per foot for cushioning, stacking, and printing
properties.
 E – second common flute, environmentally friendly with 90 flutes per foot.
 F – has small, tighter flutes, and is environmentally friendly with128 flutes per foot.
In addition to the five standard flute types, there are specialized flutes that combine or fall between the
standard flutes, such as D flutes. Specialty flutes also include EE, EF, and BC, which are often used in
double-wall profiles. Rarely used flutes like N and O are extremely small, measuring less than half a
millimeter in height.

Mullen Test (Burst Strength)

The burst strength of a corrugated box refers to the amount of force the material can withstand
before it ruptures, cracks, or falls apart. The Mullen Test, developed over 130 years ago, applies
force to the face of the corrugated material until it bursts. Results are given in pounds, indicating
the force per square inch the material can handle. For instance, a box rated at 200# can withstand
200 pounds (90 kg) of force per square inch. This test measures the amount of pressure needed to
burst through the paper on a corrugated box.

The Mullen Test provides insight into how well a box will endure handling during shipping,
including assembly operations and transit through distribution channels. It helps predict the box's
resistance to punctures and damage as it moves through various stages.

However, the Mullen Test has limitations as it does not account for the contribution of the fluted
medium to the box's strength. Although the fluted medium is crucial, contributing about 50% of
a box's stacking strength, it isn't reflected in the burst strength measurement. This is where the
Edge Crush Test (ECT) becomes valuable.
 Offset Print
Offset printing, in commercial printing, widely used printing technique in which
the inked image on a printing plate is printed on a rubber cylinder and then
transferred (i.e., offset) to paper or other material. The rubber cylinder gives great
flexibility, permitting printing on wood, cloth, metal, leather, and rough paper. An
American printer, Ira W. Rubel, of Nutley, N.J., accidentally discovered the process
in 1904 and soon built a press to exploit it.

What are the principles of offset printing?

Offset printing, as a development of lithography (q.v.), is based on the principle

that water and grease do not mix, so that a greasy ink can be deposited on
grease-treated printing areas of the plate, while nonprinting areas, which hold
water, reject the ink. The offset plate is usually of zinc or aluminum or a
combination of metals, with the surface treated to render it porous and then coated
with a photosensitive material. Exposure to an image hardens the coating on
printing areas; the coating on nonprinting areas is washed away, leaving wetted
metal that will reject ink.

Main Parts of Printing:

Modern offset printing is done on a press composed basically of three rotating

cylinders: a plate cylinder, to which the thin, flexible metal plate is fastened; a
blanket cylinder covered by a sheet of rubber; and an impression cylinder that
presses/carries the paper into contact with the blanket cylinder.

The plate cylinder first comes in contact with a series of moistening rollers that
deposit moisture in the granulations of the metal. A series of inking rollers then
pass over the plate, and the ink is rejected by the water-holding areas and accepted
by the greasy image. The inked image is transferred to the rubber blanket and is
then offset to the paper travelling around the impression cylinder.
In the lithographic process, ink is applied to a grease-treated image on the flat printing surface;
nonimage (blank) areas, which hold moisture, repel the lithographic ink. This inked surface is then
printed—either directly on paper, by means of a special press (as in most fine-art printmaking), or onto a
rubber cylinder (as in commercial printing).
 Types of Paper

1. Duplex Board

Duplex board comes in several types, primarily differentiated by the color and
coating of their two layers. Common types include White Back Duplex Board &
Grey Back Duplex Board
By Color :

 White Back Duplex Board:

Features a white surface on one side and a grey or white back.

 Grey Back Duplex Board:

A grey back is a common feature, with the other side typically coated white

Different Types of Duplex Boards

 White Back Duplex Boards.

 Grey Back Duplex Boards.
 Uncoated Duplex Boards.
 Coated Duplex Boards.
 Kraft Papers.

Uncoated Duplex Board:

This type has a rough, uncoated surface on both sides, offering strength and
durability.

Coated Duplex Board:

One side is coated for printability and a smooth finish, while the other side might
be uncoated for structural support