Industrial bags made from LDPE film: bespoke production, choice of size and raw material

What is an LDPE industrial bag?

The LDPE industrial bag is a film product made from low-density polyethylene, which is used for industrial, warehousing, packaging, waste collection or logistics purposes.

LDPE is a flexible material that is easy to process and can be manufactured in a range of thicknesses, making it suitable for the production of various types of bags.

Industrial sacks can be made, for example:

• made from virgin LDPE,
• made from recycled LDPE regranulate,
• Made from PCR raw materials,
• Made from PIR material,
• made from a blend of virgin and recycled raw materials,
• in the version with additives,
• in custom sizes and thicknesses.

Choosing the right industrial bag always depends on its intended use. Different bags are required for collecting light packaging materials, for heavier industrial waste, for internal warehouse logistics, and for products where a cleaner appearance or odour neutrality is important.

What are industrial sacks used for?

Industrial sacks have an extremely wide range of applications. In the manufacturing and processing industries, they are often ancillary products without which day-to-day operations, packaging, waste management or internal material handling would be more difficult.

Examples of their uses include:

• for the collection of production waste,
• for the packaging of industrial components,
• for the protection of raw materials or semi-finished products,
• in internal logistics processes,
• for warehouse packaging,
• for the management of packaging waste,
• for packaging textiles, clothing, furniture or mattress-type products,
• for use in the construction industry or in industrial settings,
• for waste collection companies,
• for wholesale resale.

During the client interview, it was mentioned that industrial sacks are supplied to a number of different sectors, and that industrial sacks made from regranulate also feature indirectly in the supply chains of large manufacturing companies. 

Why is bespoke manufacturing important for industrial sacks?

In an industrial setting, using the same type of bag for every task is rarely a good solution. A bag that is too small, too thin or made from unsuitable material can cause ongoing problems. A bag that is too large or too thick, on the other hand, can lead to unnecessary material wastage and higher costs.

The aim of bespoke manufacturing is to ensure that the bag is precisely tailored to its intended use.

An example of something unique might be:

• the width of the bag,
• the length of the bag,
• the thickness of the film,
• the type of raw material,
• the proportion of recycled content,
• the colour,
• the packaging,
• the perforation,
• welding,
• winding,
• the addition of additives,
• printing.

A well-designed industrial bag is not necessarily the thickest or most expensive product, but rather the one that offers the right load-bearing capacity, ease of handling and value for money for the specific task.

What raw material can be used to make LDPE industrial bags?

The choice of raw material for industrial sacks determines the product’s quality, price, odour, tear resistance, processability and sustainability.

Primary LDPE raw material

Primary, or first-grade, LDPE raw material comes directly from the raw material manufacturer. Its quality is generally consistent; it is pure, easy to process, and may be appropriate for applications where there are higher standards of purity, odour neutrality or technical specifications.

Examples of situations where a primary raw material may be justified include:

• when packaging more delicate products,
• in the case of bags with a very clean appearance,
• in an odour-neutral packaging environment,
• in the event of specific technical requirements,
• if the partner specifies audited primary raw materials.

At the same time, in many industrial applications, virgin raw materials are not strictly necessary if recycled LDPE is capable of fulfilling the required function.

Recycled LDPE regranulate

Recycled LDPE regranulate is made from plastic that has previously been used or that originates from industrial processes. The waste or by-product is processed, cleaned, ground, regranulated and then transformed into a raw material that can be reused.

In the case of industrial sacks, recycled raw materials can often be a good choice, as the sack’s intended use frequently allows for the use of regranulate.

A particularly good solution might be:

• for garbage bags,
• for industrial sacks,
• for industrial use,
• for the management of packaging waste,
• for products that do not have a strong odour,
• for thicker bags,
• cost-effective for B2B use.

Recycled raw materials play a key role in the company’s profile: according to the interview, a significant proportion of the product portfolio is made from regranulate, and the company is familiar with and uses both PCR and PIR types of raw materials. 

PCR or PIR raw material for industrial sacks?

When it comes to recycled industrial sacks, it is important to distinguish between PCR and PIR raw materials.

PCR raw material

PCR, or post-consumer recycled material, is made from plastic waste collected after consumer use.

The advantage is that it recycles genuine consumer waste back into the economy. This is an important value from a sustainability perspective.

Industrial bags made from PCR raw material may be a good choice:

• for the collection of industrial waste,
• for industrial sacks,
• for outdoor use or in situations where odour sensitivity is less of an issue,
• for thicker products,
• for tasks where visual appearance is not a priority.

PIR raw material

PIR, or post-industrial recycled material, is derived from industrial manufacturing by-products. It is typically of a cleaner, more controlled origin, and may therefore often be a better choice for more sensitive industrial packaging.

PIR as a raw material may be advantageous:

• for indoor use,
• in the case of products that are more sensitive to odours,
• when packaging textiles or clothing,
• in the case of furniture or mattress-type products,
• for bags that require a neater appearance,
• when it comes to more consistent quality standards.

The right decision is not whether to choose PCR or PIR, but what function the industrial bag in question is intended to fulfil.

What thickness should an industrial sack be?

The thickness of industrial sacks is usually specified in microns. The appropriate thickness always depends on the intended use.

A different thickness might be ideal:

• for light packaging waste,
• for heavier production waste,
• for sharper components,
• for indoor warehouse use,
• for outdoor storage,
• for mechanical or manual handling,
• for longer-term storage.

A bag that is too thin may tear or develop holes easily. A bag that is too thick, on the other hand, may result in unnecessary use of raw materials, higher costs and a greater amount of waste.

Therefore, the ideal industrial bag is not necessarily the thickest one, but the one that is suited to the required load.

Why isn’t it enough just to look at the micron value?

Thickness is important, but on its own it does not tell the whole story about the quality of an industrial bag.

The bag’s actual usability is influenced by:

• the quality of the raw material,
• the purity of the regranulate,
• the elongation of the film,
• tensile strength,
• the quality of the weld,
• the size of the bag,
• the design of the bag,
• any additives,
• the operating environment.

There can be a significant difference even between two industrial bags of the same thickness. A thicker bag made from a poorer-quality raw material may perform less well in use than a thinner bag made from a well-chosen raw material but manufactured to a high standard.

What size of industrial sack should you choose?

When choosing a size, the most important thing is that the bag is suitable for its intended purpose.

It is worth clarifying:

• what sort of product or waste goes into it,
• how much it needs to hold,
• which type of collection vessel or technological process it is suitable for,
• whether it is moved by hand or by machine,
• Is a rollback necessary,
• how is the closure carried out,
• whether a roll-type or sheet-mounted version is required.

An oversized bag may result in unnecessary use of material. An undersized bag, on the other hand, is difficult to use, tears more easily and can slow down the workflow.

Precise sizing can lead to significant savings, particularly on large orders.

What specific features might be required?

In the case of industrial sacks, certain applications may require specific properties.

Antistatic industrial bag

In certain industries, it may be important for the film to have antistatic properties. This may be particularly relevant if the packaged product, the environment or the manufacturing process is sensitive to electrostatic charging.

Antistatic additives might be considered, for example:

• in the electronics industry,
• for certain applications in the textile or clothing industry,
• in a dusty environment,
• in specialised packaging processes.

One example mentioned in the interview was an anti-static flat film which had previously been made from virgin raw materials, but which the partner was subsequently able to produce using recycled raw materials in line with their requirements. 

UV-stabilised industrial bag

If the industrial bag is to be used outdoors or is exposed to sunlight for a prolonged period, UV stabilisation may be required.

A UV-stabilised design may be appropriate:

• when stored outdoors,
• in a construction environment,
• for agricultural use,
• when protecting goods on pallets,
• for longer-term outdoor waste collection.

Without UV stabilisation, the film may age prematurely, become brittle and tear.

Bags made from odour-reduced or cleaner raw materials

For indoor use or in odour-sensitive environments, it may be important that the industrial sack does not give off an unpleasant odour.

In such cases, it may be worth:

• to choose a purer regranulate,
• To think in terms of PIR as a raw material,
• mix with the base material,
• to use an odour-reducing additive,
• request a sample and test it.

This is particularly important for industrial bags designed for packaging textiles, clothing, mattresses, furniture or other odour-sensitive products.

Coloured or printed industrial sacks

Industrial bags can be produced in a variety of colours or even with printed designs.

The purpose of this may be:

• product identification,
• classification of waste types,
• corporate identity,
• support for the logistics system,
• wholesale sales,
• displaying usage information.

It was mentioned in the interview that the company is able to print on film products in several colours, which could be useful for both bags and flat films. 

Steps in the manufacture of industrial sacks

The manufacture of industrial sacks consists of several interlinked stages.

1. Determining the intended use

Firstly, it is important to clarify exactly what the bag will be used for. This will determine the main considerations regarding the material, thickness, size and design.

2. Selection of raw materials

The bag can be made from virgin LDPE, recycled regranulate or a mixture of the two. The choice of raw material depends on requirements relating to mechanical properties, odour, cost and sustainability.

3. Extrusion of film

The raw material is extruded to produce film or tubular film. It is at this stage that the film’s width, thickness, structure and basic technical properties are determined.

4. Garment manufacturing

A bag of the required size is formed from the film or tubing. This may involve cutting, welding, perforating, rolling or assembling into sheets.

5. Quality control

The finished product must be inspected for dimensions, thickness, welds, tear resistance, elongation and suitability for use.

6. Packaging and delivery

The bags can be delivered in rolls, on sheets or in other formats, depending on the customer’s requirements.

What kind of quality control is important for industrial sacks?

In the case of industrial sacks, the aim of quality control is to ensure that the product performs reliably during use.

Key assessment criteria:

• thickness,
• width and length,
• dimensional stability,
• tensile strength,
• stretching,
• weld quality,
• puncture resistance,
• smell,
• surface appearance,
• the quality of the winding or packaging.

According to the interview, the manufacturer has its own laboratory where it can test, amongst other things, the elongation, tear strength and physical properties of its film products. 

This is particularly important in the case of industrial sacks made from recycled raw materials, as the quality of the regranulate can have a significant impact on the end result.

Common mistakes when ordering industrial sacks

1. They base their decision solely on price

When it comes to industrial sacks, price is an important consideration, but it cannot be the only deciding factor.

A cheaper but weaker bag may tear during use, leading to rejects, slowing down the work or generating extra waste. In such cases, the lower unit price may result in higher overall costs.

2. The intended use is not specified

If the manufacturer does not know exactly what the bag is to be used for, it is more difficult to recommend the appropriate size, thickness and material.

Saying “I need an industrial bag” is too vague. It is important to know what kind of product or waste will be placed in it, what load it will bear, whether it will be used indoors or outdoors, and what other requirements there are.

3. They use an oversized bag

Many companies reorder the same size out of habit, even though the bag may be too large or too thick for the task at hand.

Oversizing leads to unnecessary use of materials and higher costs.

4. They choose a bag that is too small

A bag that is too thin or too small can tear easily, is difficult to handle, and does not fulfil its purpose properly.

This can be a particular problem in industrial environments, where the sacks are subjected to greater loads.

5. The new raw material is not being tested

If you are switching from virgin raw materials to recycled raw materials, it is worth requesting a sample and testing the bag in its actual operating environment.

This helps to avoid problems arising from tearing, odour, size or workability.

When should you choose an industrial bag made from recycled materials?

Industrial bags made from recycled LDPE raw material may be a good choice if:

• the bag is intended for waste collection or industrial use,
• complete odour neutrality is not necessary,
• this does not concern direct food packaging,
• Value for money is important,
• recycled content is important,
• the regranulate fulfils the function of the film as required,
• The appropriate thickness and welding for the product can be ensured.

A recycled industrial bag is not a compromise solution if it is made from the right raw materials and with the right manufacturing expertise.

When might a primary raw material be the better choice?

The use of primary LDPE as a raw material may be justified if:

• the bag is used to pack a delicate product,
• It is important to be completely odourless,
• there are high standards of cleanliness,
• specific technical requirements must be met,
• the partner specifies audited raw materials,
• a very thin or specialised film needs to be manufactured,
• its use is directly linked to the food industry.

A good manufacturing approach is not about using recycled materials or virgin raw materials at all costs, but about choosing the best technical and economic solution for the application in question.

How can optimising industrial bags help?

When it comes to industrial sacks, even minor adjustments can yield significant results when produced in large quantities.

For example, the following can be optimised:

• the size of the bag,
• the thickness,
• the composition of the raw materials,
• the proportion of recycled content,
• welding,
• the packaging,
• the packaging unit,
• the delivery schedule.

If the bag is too large, too thick or unsuitable for the task, it can result in ongoing unnecessary costs. If, on the other hand, it is too flimsy, it can lead to waste, problems and disruptions to the workflow.

The ideal industrial bag is designed to meet the exact requirements of its specific application.

Large orders: what should a buyer be prepared for?

Before placing an order for large industrial sacks, it is worth gathering the most important information in advance.

Useful information for requesting a quote:

• type of bag,
• intended use,
• size,
• thickness,
• required quantity in pieces or kilograms,
• requirements relating to raw materials,
• the need for recycled content,
• colour,
• packaging,
• additive requirement,
• place of delivery,
• planned order frequency,
• required documentation.

It was mentioned in the interview that the general minimum order quantity 500 kg / type, order confirmations are typically issued within 24 hours, and delivery can usually be arranged within 3–4 weeks. 

For this reason, in the case of regular industrial use, it is advisable to plan ahead rather than leave procurement until the last minute.

Sustainability and industrial bags

In the case of industrial sacks, the use of recycled raw materials can serve both economic and sustainability objectives.

LDPE industrial bags made from regranulate:

• may reduce the use of primary raw materials,
• can help with the recycling of plastic waste,
• can support the circular economy,
• may contribute to a more sustainable use of packaging materials,
• It may also be beneficial from an ESG perspective, provided it is properly documented.

However, it is important that sustainability communications are accurate. Not all recycled raw materials are the same, and the same formulation is not suitable for every product.

It is more credible to state the proportion and type of recycled raw materials contained in a given industrial bag, as well as the intended use for which it was designed.

What sort of documentation might be important for industrial partners?

Proper documentation may be important when dealing with major industrial partners, in audited supplier systems, or in ESG reporting.

Examples of this might include:

• quality certificate,
• information on the composition of raw materials,
• measurement of physical properties,
• Statement on reused content,
• REACH compliance information,
• Supplementary data that can be used for ESG reporting.

Based on the customer interview, the manufacturer will, upon request, issue a quality certificate for the product in question, which may include measurements of its physical properties and information on its material composition. 

This could be particularly useful for companies that are not just looking for packaging materials, but for a documented, long-term and reliable supply solution.

Summary

Industrial bags made from LDPE film play an important role in manufacturing, packaging, waste management, warehousing and logistics. Although they may appear to be simple products, when used in large-scale industrial applications, the selection of the correct size, thickness, raw material and design is of great importance.

Industrial bags made from recycled LDPE raw material can often be a good choice, particularly for waste collection, industrial, wholesale or non-odour-sensitive packaging applications. However, for more sensitive products, indoor use or where higher cleanliness standards are required, it is worth considering PIR raw material, a formulation combined with a primer, or a fully primed solution.

A good industrial bag is not necessarily the thickest or the cheapest, but the one that is precisely suited to its intended purpose. To achieve this, it is important to consult the manufacturer, choose the right raw materials, optimise the size and thickness, and, where necessary, carry out prototyping and testing.

With the right manufacturing expertise, LDPE industrial bags can be not only a reliable and cost-effective option, but also a more sustainable packaging solution.

Frequently Asked Questions

What are LDPE industrial bags used for?

LDPE industrial bags can be used for collecting production waste, packaging industrial components, warehouse tasks, internal logistics, handling packaging waste and for wholesale purposes.

Can industrial sacks be made from recycled materials?

Yes, many industrial sacks can be manufactured effectively from recycled LDPE regranulate, particularly if the product is not odour-sensitive and does not require exceptionally pure virgin raw material.

What is the difference between PCR and PIR raw materials in industrial sacks?

PCR is made from post-consumer recycled plastic, whilst PIR is derived from industrial production waste. PCR is a raw material with high sustainability value, whilst PIR is generally a cleaner raw material with a lower risk of odour.

What thickness of industrial sack should you choose?

The appropriate thickness depends on the intended use. A thinner bag may be sufficient for lighter waste, whilst heavier, sharper or high-load industrial applications require stronger film.

Is a thicker industrial sack always better?

Not necessarily. A thicker bag may mean greater use of raw materials and higher costs. The aim is to achieve the optimum thickness, which ensures adequate load-bearing capacity without unnecessary oversizing.

When should you choose an industrial sack made from primary raw materials?

The use of a primer may be justified where complete odour neutrality, high purity, compliance with specific technical requirements or the packaging of sensitive products are important.

Is it possible to manufacture industrial sacks in custom sizes?

Yes, for larger quantities, industrial sacks can be manufactured to custom specifications in terms of size, thickness, colour, raw material composition, packaging and additives.

Why is the quality of welding important?

The load-bearing capacity of the bag is determined not only by the thickness of the film, but also by the quality of the weld. If the weld is poor, the bag may split open or tear during use.

What information should you provide when requesting a quote?

It is worth specifying the intended use, dimensions, thickness, quantity, requirements regarding the raw material, requirements for recycled content, colour, packaging, any additive requirements and the delivery terms.