Fusion: The Stitchless Bulk Bag

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Years Experience

1 +

Customers Served


Manufacturing Locations

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Countries served

1 mil

FIBCs produced per month

1 km

Proximity from Mundra Sea Port

Sewn Bulk Bags...

Traditionally, all bulk bags have been made using the process of sewing

• The process of sewing is a manual one, involving a lot of manpower and hence scope of errors

• Sewing weakens the fabric

• Due to the holes created by sewing there are chances of sifting/leakage

• These holes also reduce moisture protection

• Sewing can lead to contamination of the products

These are issues which have been around for decades. Customers have gotten used to these issues…
Fusionis the transformative solution to all these problems….

No Sifting? No Leakage?

• Every needle hole created by the sewing machine while assembling components for bulk bags is a potential agent for leakage and sifting

• To further make this worse, these holes expand when weight is applied onto them, further increasing the chance for sifting.

• The easiest way to prevent leakage through holes, is to eliminate the sewing holes

Fusion bags are made using special heat sealing technology. These bags have no needle holes in the product containment region of the bag. Making them completely sift and leak proof…..

Lower Strength Loss in Fabric

• Sewing creates a bond between two fabrics, by joining them using a sewing yarn.

• This bond only allows the fabric to retain 66% of its original strength…

• This significant reduction in inherent fabric strength forces manufacturers to use heavier fabrics, which means heavier bags

• Heavier bags are more expensive, have a higher freight cost per bag and have a higher cost of disposal.

The heat sealed fabric bonds in Fusion retain 95% of the inherent fabric strength. Allowing for lighter fabric and lighter bags. Reducing all associated costs with bulk

Eliminate Liners... Really?

• Traditionally, the best answer to moisture protection in the bulk bag industry are PE liners

• Liners can cause significant issues during bag filling and discharging.

• In worst cases, the liner may get discharged with the material contaminating the product and also the processing machinery.

• Liners also contribute significantly to the bag weight, increasing the overall cost of the bag.

• They also present additional challenges for disposal and recycling.

Fusion bulk bags are made with fabric consisting of high coating thickness, not punctured by sewing holes and so inherently moisture protective. Better protection
for the product . A boon for high value products.

No Contamination

• Sewing leads to fracture in fabric, and generation of dust from the yarn rubbing with fabric.

• In some cases, machine heads are inside the bags exposing the interior to oil and dust from the machine

• There are chances of finding sewing thread ends in the bag

Fusion bulk bags are made with all equipment contacting the fabric outside the product containment zone. The bags are flat and gusseted during the manufacturing

Is it Safe though?

• Traditionally, not all bulk bags from a lot can be tested without destroying them.

• All the current testing and inspections done on sewn bulk bags is manual and visual.

• In the Fusion bag making process there is also a non-destructive test after production, which puts every bag through testing before it gets qualified as fit to use.

• The sophisticated, computer-controlled process automatically verifies the correct placement of components, temperature variation, and other critical data points.

• These tests are performed despite fusion bags having a very high level of standardization

• 100% inspection is peace of mind for the supplier, distributor and end user.

Your opportunity to connect with one of the FIBC Industry Leaders.

Traceability, better than Sewn Bags

• The traceability system on the Fusion machine can determine when and on which machine each bag was produced.

• Each bag produced has its own unique bar code, which can be used to track various data to each bag which stores the statistics about the creation of each bond, positional issues that were fixed, test to destruction data for the related lot, and the data related to the non-destructive testing performed on the bag before shipping. Some of which are mentioned below:

  • Vision System Results
  • Bag Serial #
  • Machine Cycle Tracing
  • Fault Monitor
  • Temperature Verification
  • PSI
  • Seal Temperature
  • Overshoot Monitor
  • Seal Pressure
  • Avg. Temperature
  • Placement Faults
  • Non-Destructive Tests
  • Undershoot Monitor
  • Lot Load test
  • Seal Duration


The Need for Standardisation

• FIBCs are completely customisable in nature.

• They are assembled using several other components, each made to cater to the specific customisation

• This leads to a lot of problems for the manufacturers and distributors, essentially forcing them to keep surplus inventory.

• Custom orders, lead to added lead times as manufacturers need to make all components from scratch.

• Fusion, comes in only selective sizes. We propose the 37×37 inch square base dimension as it is perfectly suited for truck and container transportation.

• With the above mentioned sizes, the filled Fusion bag fits perfectly in a truck with minimal space for movement of bags, eventually leading to lower product losses.

Size Customisations

• Bag Sizes, square base only

Inches 35" x 35" 37"x 37" 41" x 41"
89 x 89
94 x 94
104 x 104

• Bag Heights

Min. Max

• Spout Diameters, height as per customer requirement

Inches 14'' 16'' 18''

• Loop Heights from 25-30 cm

Current Technological Limitations

•SWL: maximum 1000 kg

• Safety Factor: 5:1

• Only Cross Corner Loops

•All Document Pockets to be glued onto the bags

• Printed Bags possible , but for maximum 2 sides and 4 colour

• Only available in Type A, Type B and Type D


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