Six Stages. One Roof. No Handoffs.
Most of the world's FIBC supply is assembled, not manufactured. Fabric and webbing are purchased on the open market, cut, stitched and shipped. That business model has one structural weakness: the most vital properties of the bag — tape tensile strength, fabric weight, coating integrity — are decided by an upstream vendor the customer never speaks to.
Coastal FIBC operates the complete chain. Polypropylene arrives as virgin polymer resin. It leaves as a certified, tested bag.
The Six Stages of In-House Production
Photographed live on location inside our Rajkot manufacturing plant.
Extrusion and Tape Making
100% virgin polypropylene granules are extruded into high-tensile film and slit into precise tapes, then stretched and thermally oriented. This is where the molecular tensile strength of the bag is born. Because we extrude in-house, yarn denier and tensile properties are custom-formulated per order.
Circular & Sulzer Weaving
Polypropylene tapes are woven into structural fabric on heavy-duty flat and circular looms. Circular looms produce the seamless tubular cylinders used in our circular bags — fabric that eliminates vertical side seams. Weave picks and warp tension are calibrated exactly to the cargo's bulk density.
High-Tenacity Webbing Manufacture
Lifting loops carry the full dynamic weight of the load. We weave our own high-tenacity polyester and polypropylene webbing in-house. Webbing tensile strength is an engineered, measured design factor rather than a purchased third-party variable.
Extrusion Coating & Lamination
A hot extruded polyethylene coating (25–35 GSM) is laminated directly to the woven fabric, sealing micro-pores against fine powder migration and atmospheric humidity. Both coated barrier fabric and breathable uncoated fabrics are produced under strict temperature control.
Four-Colour Flexographic Printing
Crisp in-house flexographic printing in up to 4 colours. Essential for mandatory hazardous goods pictograms, multi-language handling instructions, barcode labels, and brand identity, proofed prior to production runs.
Cleanroom Assembly & Stitching
Precision hot-knife and ultrasonic automated cutting ensures clean, sealed edges that prevent yarn fraying. Spouts, baffles, skirts, and body panels are assembled by skilled operators using heavy-duty chain stitching and multi-cord dust-proofing.
What Vertical Integration Buys You
A Specification That Holds
The fabric that passed your initial qualification is produced on our looms, to recorded parameters, for repeat orders. Nothing shifts because a broker swapped yarn vendors.
End-to-End Traceability
Every shipment connects back through stitching, assembly, coating, weaving and resin extrusion lot numbers. No blind spots in the quality audit.
Schedules We Control
3.5M+ annual capacity means orders are scheduled across dedicated in-house production lines, insulating export dates from vendor delays.
Direct Accountability
Integrated manufacturing leaves no gap where a defect is blamed on an external supplier. Everything happens in our plant, and our engineers stand behind it.
Arrange a factory visit or live video plant walkthrough.
Buyers placing substantial export volume are welcome in Rajkot. If travel is not convenient, we will walk you through extrusion, weaving, coating, and the test rig on a live video tour.