Reusable bags are LeKAC’s signature product. We offer a wide range of materials, finishes, and styles of reusable bag to suit all kinds of business’ needs. The construction of these bags may seem like a mystery, but it’s actually quite simple!
In this blog post, we’ll walk you through the process of making our non-woven polypropylene (PP) reusable bags. Read on to learn more!
The key draw of reusable bags is that they use fabrics rather than plastics. We melt PP pellets and spin them into filaments that we press into sheets and roll into spools of fabric. The non-woven PP material comes in a set range of colours for clients to choose from. We cut the sheets to the correct size later on in the production process.
The second phase of the reusable bag making process is printing! Once we receive approval to proceed to mass production, we begin printing designs onto the bag material. There are three main printing methods that we use in this phase of the production process:
Screen Printing – If you’ve read our previous blog post on reusable bag printing techniques, this technique may be familiar to you. Screen printing–also known as silk screen printing–involves a mesh screen and blocking stencil. This technique is best for simple designs with solid colours.
Lamination – Lamination uses either digital or CMYK printing on top of a film that is placed on top of the non-woven PP material. This film can be either matte or glossy, depending on the effect you’re looking for. Overall, this technique is best for designs that have a lot of detail, or for making items water-resistant.
Digital – Similar to CMYK print, digital printing also uses this colour system. However, the main difference between a normal CMYK print and a digital print is in the number of colours that are available to print. Additionally, digital print is usable on a wider variety of surfaces.
You can apply screen printing and some CMYK prints using machines or manually. Since CMYK prints are achievable by layering the various colours together, simple CMYK prints may also be possible using screen printing.
Machine screen printing prints all the designs at once on the entire length of fabric before cutting it to size. Conversely, in manual screen printing, fabric is cut before the printing process begins.
Cut & Convert
After deciding on the printing method, the bag materials are cut to the correct sizes. This happens manually or using automation. Once this step is complete, the bags enter the conversion stage, which includes putting the pieces together for construction. Heat sealing and manual stitching are the two main construction methods. What’s the difference between the two?
- Seams pressed together using heat
- Handles attached using heat press
- Fewer pieces to connect
- Machine stitching for seams
- Handles attached using cross stitch for extra stability
- Contrasting edge piping colours available
In this stage of production, the supplier will usually also include the bag handles. We call the second part of this stage conversion since the fabric is converted from flat, individual pieces to usable bags!
Finally, the bags are ready to pack for shipping. A worker packs the bags manually, and seals them for shipping. From there, our production team coordinates with the supplier to send them to your business.
Advantages Of Using Reusable Bags
Especially with the upcoming plastic ban, our reusable bags are a great option for any business looking to transition away from plastic. These bags have a wide variety of customizations available, and other bag styles are available depending on your needs. These bags can also provide customers with long-term brand recognition, since your brand is visible on the front!
Interested in creating some plastic bags for your business? Contact us today and get connected with one of our knowledgeable Business Development consultants who can let you know more!