Fabric rolls nobody can find
Every roll gets a number, loom, width, GSM and weight when it comes off the loom, so roll-wise stock is always current.
PP/HDPE woven sacks, FIBC, leno and BOPP bags
Woven Sack & FIBC ERP software
Built for woven sack and FIBC plants, from resin and masterbatch receipt through tape extrusion, circular weaving, coating, lamination, printing and stitching to baled dispatch, with roll-wise stock and lot-wise traceability throughout.
Quick answer
What is woven sack and FIBC ERP?
Woven sack and FIBC ERP is business software built around how a woven bag plant runs. Formezy records each resin and masterbatch lot, the recipe used at the tape line, denier and output per shift, every fabric roll from the looms, coating and lamination, bags made per operator and the test results for each lot, so stock, wastage and cost stay current from granule to bale.
Wastage hidden between stages
Tape, fabric, cutting and stitching waste is booked by stage and type, and regrind returned to stock, so losses show where they happen.
Test records kept on paper
Tape, fabric and bag test results, including SWL tests for FIBC, are stored against the lot and travel with the dispatch.
Segments
Built for every woven sack & FIBC segment
4 segments, each with its own shop-floor process flow.
PP/HDPE woven sacks
Woven polypropylene and HDPE sacks for cement, fertiliser, grain, sugar and chemicals. Track the recipe at the tape line, denier per shift, every fabric roll and bags produced per operator.
See the 8-step flowFIBC / jumbo bags
Flexible intermediate bulk containers with loops, spouts, liners and baffles. Track coated fabric rolls, panels cut per design, bags stitched per operator and the SWL test results for every design and lot.
See the 7-step flowLeno / mesh bags
Open-mesh leno bags for onions, potatoes, fruit and firewood. Narrow tapes, leno loom output and bag weights tracked per shift.
See the 6-step flowBOPP laminated bags
Woven bags laminated with reverse-printed BOPP film for rice, flour, pet food and retail packs. Film, ink and lamination tracked per roll and order.
See the 6-step flowShop-floor process flow
How Formezy runs a woven sack & FIBC plant
Choose a segment, then a step. Each one shows what happens on the shop floor, what Formezy records, and what changes as a result.
On the shop floor
PP/HDPE granules, filler and UV/colour masterbatch bags received and weighed
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Resin lot traced from day one
On the shop floor
Resin, filler and masterbatch weighed and mixed for the tape line
In Formezy ERP
Approved recipe issued with the job; actual weights booked against the lots used
Production & Purchase moduleShop-floor impact
Recipe followed, cost known
On the shop floor
Film extruded, slit into tapes, stretched and wound on bobbins
In Formezy ERP
Output (kg/hr), denier and bobbin weights logged per shift with downtime reasons
IoT & Automation moduleShop-floor impact
Output and denier per shift
On the shop floor
Denier, tenacity and elongation tested on bobbin samples
In Formezy ERP
Results recorded against the tape batch; out-of-spec bobbins put on hold
Quality Control moduleShop-floor impact
Only in-spec tape reaches looms
Quality gate. If it fails: adjust the line and send off-spec tape to regrind.
On the shop floor
Tapes woven into tubular fabric on circular looms
In Formezy ERP
Roll created with loom no., width, mesh, GSM and roll weight; loom efficiency per shift
Production & Purchase moduleShop-floor impact
Roll-wise stock, live
On the shop floor
Fabric printed with the customer's artwork
In Formezy ERP
Print job linked to roll numbers; ink consumption booked per order
Production & Purchase moduleShop-floor impact
Ink cost per order
On the shop floor
Fabric cut to bag length and bottom stitched
In Formezy ERP
Bags counted per operator; fabric issued reconciled with bags made and waste booked
Production & Purchase moduleShop-floor impact
Fabric-to-bag yield visible
On the shop floor
Bags counted into bales, pressed, weighed and loaded
In Formezy ERP
Bale labels, packing list, invoice and e-way bill from the same record
Logistics & Dispatch moduleShop-floor impact
No manual packing lists
PP/HDPE woven sacks, step 1 of 8
Resin receipt
On the shop floor
PP/HDPE granules, filler and UV/colour masterbatch bags received and weighed
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Resin lot traced from day one
On the shop floor
Woven fabric rolls, webbing, thread and liners received
In Formezy ERP
Rolls tagged with roll no., GSM, width and weight; webbing and liners stocked by lot
Inventory moduleShop-floor impact
Roll-wise stock from day one
On the shop floor
Fabric extrusion-coated for moisture-resistant bags
Shop-floor impact
Coating cost per roll
On the shop floor
Body, top, bottom and spout panels cut to the bag design
In Formezy ERP
Cutting plan from the bag specification; panels counted and offcuts booked
Production & Purchase moduleShop-floor impact
Fabric per bag known
On the shop floor
Panels, loops, spouts, baffles and liners stitched by operators
In Formezy ERP
Bags per operator and stitching line per shift; thread and webbing consumed per bag
Human Resources moduleShop-floor impact
Operator output visible
On the shop floor
Dimensions, loops and stitching checked; designs top-lift tested to the specified safety factor
In Formezy ERP
Safe working load, safety factor and test results stored against the design and production lot
Quality Control moduleShop-floor impact
Test record for every lot
Quality gate. If it fails: hold the lot, rework or retest, or scrap.
On the shop floor
Bags cleaned, folded and baled with lot labels
Shop-floor impact
Every bale identifiable
On the shop floor
Bales loaded against the customer order
In Formezy ERP
Packing list, invoice and test documents generated together
Logistics & Dispatch moduleShop-floor impact
No paperwork chase
FIBC / jumbo bags, step 1 of 7
Fabric receipt
On the shop floor
Woven fabric rolls, webbing, thread and liners received
In Formezy ERP
Rolls tagged with roll no., GSM, width and weight; webbing and liners stocked by lot
Inventory moduleShop-floor impact
Roll-wise stock from day one
On the shop floor
PP granules and colour masterbatch received and weighed
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Lot traced from day one
On the shop floor
Narrow coloured tapes extruded and wound
In Formezy ERP
Recipe, output and denier logged per shift; colour change time recorded
IoT & Automation moduleShop-floor impact
Colour changes costed
On the shop floor
Tapes woven into open mesh on leno looms
In Formezy ERP
Mesh rolls created with loom no., width and weight; loom stoppages with reasons
Production & Purchase moduleShop-floor impact
Loom stoppages explained
On the shop floor
Mesh cut, stitched and fitted with drawstrings or labels
In Formezy ERP
Bags counted per operator; mesh and drawstring consumption booked
Human Resources moduleShop-floor impact
Material per bag known
On the shop floor
Bag weight, size, mesh and stitching checked on samples
Shop-floor impact
Light bags caught early
Quality gate. If it fails: rework or send to regrind.
On the shop floor
Bags baled, weighed and loaded
Shop-floor impact
Bale count matches invoice
Leno / mesh bags, step 1 of 6
Resin receipt
On the shop floor
PP granules and colour masterbatch received and weighed
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Lot traced from day one
On the shop floor
BOPP film rolls received; woven fabric issued from weaving
In Formezy ERP
Film micron, width and weight posted; fabric rolls issued against the order
Inventory moduleShop-floor impact
Film and fabric per order
On the shop floor
BOPP film reverse printed in multiple colours
In Formezy ERP
Print job, cylinders used, ink and solvent consumption booked per job
Production & Purchase moduleShop-floor impact
Print cost per job
On the shop floor
Printed film extrusion-laminated to woven fabric
In Formezy ERP
Laminated rolls created with lamination GSM and weight, linked to film and fabric rolls
Production & Purchase moduleShop-floor impact
Film-to-fabric traceability
On the shop floor
Bond strength, print registration and appearance checked
Shop-floor impact
Only good rolls converted
Quality gate. If it fails: hold the roll, re-laminate or downgrade.
On the shop floor
Rolls cut, gusseted and bottom stitched or block-bottomed
Shop-floor impact
Conversion yield per order
On the shop floor
Bags counted, baled and loaded
Shop-floor impact
Order-wise dispatch
BOPP laminated bags, step 1 of 6
Film & fabric receipt
On the shop floor
BOPP film rolls received; woven fabric issued from weaving
In Formezy ERP
Film micron, width and weight posted; fabric rolls issued against the order
Inventory moduleShop-floor impact
Film and fabric per order
Dashed ring marks a quality gate, where failed material is held before it moves on.
Capabilities
What Formezy covers in woven sack & FIBC
Open an area to see what it covers.
Roll numberingEvery fabric and laminated roll tagged with loom, width, GSM and weight.
Lot traceabilityResin and masterbatch lots linked to tapes, rolls, bags and bales.
Multiple unitsKilograms, metres, rolls, bags and bales handled side by side.
Stock searchFind rolls by GSM, width, colour, lamination or order.
Regrind stockWaste returned as regrind and reused in later recipes.
Recipe managementResin, filler and masterbatch percentages per product.
Shift-wise outputTape line, loom and stitching output by shift and operator.
Loom efficiencyRunning, stopped and changeover time per loom.
Process-wise costingCost per kilogram and per bag at each stage.
Stage-wise wastageTape, fabric, cutting and stitching waste booked by type.
Tape and fabric testsDenier, tenacity, GSM and mesh recorded per batch.
FIBC test recordsSWL, safety factor and top-lift results per design and lot.
HoldsFailed tapes, rolls and lots held until cleared.
Bale labelsBale labels and packing lists printed from the record.
GST and e-way billsInvoices and e-way bills from the dispatch record.
Questions
Woven Sack & FIBC ERP: common questions
Still have a question?
Talk to a plastic ERP specialist about your own plant and process route.
Which woven sack & FIBC segments does Formezy support?
Formezy supports PP/HDPE woven sacks, FIBC / jumbo bags, leno / mesh bags and BOPP laminated bags, each with its own process flow. Plants that combine segments run them in one system.
Does Formezy support both woven sacks and FIBC?
Yes. The same system runs tape extrusion, weaving, coating, lamination, printing, cutting and stitching, so a plant making woven sacks, FIBC, leno bags and BOPP laminated bags works on one record.
How does Formezy track fabric rolls?
Each roll is numbered when it leaves the loom, with loom number, width, GSM and weight. Coating, lamination and printing keep the link to the original roll, so any bag lot traces back to its rolls, tapes and resin lots.
Can it record tape denier and loom efficiency?
Yes. Denier, tenacity and line output are recorded per shift for each tape line, and loom running, stoppage and changeover time are logged with reasons, so efficiency is visible per loom and shift.
How are FIBC SWL tests recorded?
Safe working load, safety factor and top-lift test results are stored against the bag design and the production lot. Lots can be held until results are entered, and the documents go out with the dispatch.
Does it handle regrind and recycled material?
Yes. Waste from each stage is booked by type and weight, regrind is returned to stock, and recipes can include a set regrind percentage so its use is tracked.
Can it calculate the cost of a bag?
Yes. Resin, filler, masterbatch, ink, lamination film, thread, webbing and labour are booked against the order, so cost per kilogram and per bag comes from actual consumption.
Other industries
Ready to run your woven sack & FIBC plant on one system?
See Formezy configured around your own process route, from receipt to dispatch.