Complete Bag Manufacturing Factory Solution
1. Preliminary Needs Assessment
1.1 Client Interview Questionnaire
- Product Types: Vest bags/garbage bags/food bags/medical bags/biodegradable bags etc.
- Capacity Requirements: Daily output (kg or pieces), future expansion plans
- Material Process: PE/PP/biodegradable materials (PLA/PBAT), printing requirements (cylinder count, color sets)
- Factory Status: Ceiling height, power capacity (380V/220V), air supply conditions, logistics channels
1.2 Basic Data Collection Form
| Item | Client Input | Remarks |
|---|
| Factory Area | Length __m × Width __m | Including storage area |
| Target Daily Output | __ tons/day | List by specifications |
| Power Configuration | Existing __kVA | Capacity expansion needed? |
| Employee Skill Level | Skilled/Semi-skilled/Novice | Training needs assessment |
2. Factory Planning & Layout Design
2.1 Functional Zone Division
- Raw Material Zone: Constant-temperature drying room (RH≤30% for PLA materials)
- Production Zone: Blown film + printing + bag making (U-shaped layout recommended for space saving)
- Post-Processing Zone: Inspection table (with LED light source) + counting & stacking machine
- Warehousing Zone: Recommend 15% buffer area (film rolls require vertical storage)
2.2 3D Layout Delivery
Using AutoCAD/FlexSim to provide:
- Equipment positioning diagram (with minimum maintenance spacing)
- Material flow simulation (avoid cross-contamination)
- Emergency evacuation channel design
3. Equipment Configuration Plan
3.1 Core Equipment Selection Matrix
| Process | Economy Configuration | High-Efficiency Configuration | Smart Configuration |
|---|
| Film Blowing | Single-layer screw Φ65mm | Five-layer co-extrusion (with online thickness measurement) | IoT die head auto-adjustment system |
| Printing | 4-color gravure (mechanical shaft) | 8-color satellite type (servo drive) | Pre-installed CCD registration system |
| Bag Making | Hot-cut vest bag machine (60pcs/m) | Three-side seal continuous roll machine (120pcs/m) | Robotic auto-palletizing integration |
3.2 Auxiliary System Configuration
- Central feeding system (saves 15% labor)
- Edge trim recycling pelletizing device (recovery rate ≥85%)
- VOCs treatment equipment (for solvent-based ink workshops)
4. Capacity Calculation & Staffing
4.1 Standard Capacity Model
Example for 20×30cm vest bags:
- Film blowing unit: 450kg/8h (LDPE melt index 2.0)
- Bag making machine: 220,000 pieces/shift (dual-head configuration)
- Required operators: 3/shift (1 lead + 2 assistants)
4.2 Automation Level Comparison
| Automation Level | Per Capita Output Value | Applicable Client Type |
|---|
| Basic | ￥80,000/year | Startups |
| Intermediate | ￥150,000/year | Medium OEM factories |
| Full Automation | ￥300,000/year | Brand-owned factories |
5. ROI Analysis
5.1 Typical Investment Structure
- Equipment: 60% (including installation)
- Factory modification: 15% (including power capacity expansion)
- Working capital: 25% (3-month raw material reserve)
5.2 Break-even Calculation
Assumptions:
- Total equipment investment: ¥2.8 million
- Average bag price: ¥0.12/piece
- Variable cost: ¥0.085/piece
Break-even point = Fixed cost / (Price - Variable cost)
= ¥1,200,000/year ÷ (0.12-0.085)
≈ 34 million pieces/year
6. Implementation Support
6.1 Phased Delivery Plan
- Month 1: Foundation embedding (requires client preparation)
- Month 2: Equipment installation (providing hoisting plan)
- Month 3: Trial production (raw materials procured by us)
6.2 Training System
- Basic operation: 30 hours (including equipment safety)
- Advanced maintenance: 16 hours (die cleaning/PLC troubleshooting)
- Certification: Operation qualification certificate
7. Value-Added Services
- Remote diagnostic system (annual fee, includes 2 expert sessions/month)
- Spare parts inventory hosting (10% deposit, pay-as-you-use)
- Technology upgrade buyback (15% trade-in value for old equipment)
Deliverables List
- Customized Factory Planning White Paper (with equipment specs)
- Dynamic ROI calculator (Excel adjustable version)
- Reference client visits (3 operational case studies)
- Local environmental compliance guide (with application flowchart)
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