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Manufacture Process

At the beginning of 2017, we invested £2.5 million pounds into a new factory to ensure the highest quality mailbags are produced. Below is a brief step by step guide as to how we produce our mailbags.

  1. Gathering Raw Materials

    The first procedure in the production line is to gather the raw materials necessary to produce the mailbags. Polyethylene (PE) is the most common polymer in the world, due to its wide range of possible uses. Using our 15 years of manufacturing experience, we determine which resin is the best quality and most suitable, as this can come from a variety of recycled sources. By doing this, it allows us to produce the best quality mailbags.

    (Plastic Resin)



        2. Film Blowing Process

    The second procedure in the production line is the blown film extrusion process. The small plastic pellets are blended then melted to 176°C under controlled conditions until they are molten and pliable.

    • They are then extruded to form a continuous tube of plastic.
    • Co-extrusion technology, allows us to produce the bags with three layers of polythene film compressed into one.
    • Whilst in molten state, the film is then inflated and stretched to the desired thickness.
    • After this, the film goes through a cooling process before being cut to the desired size.

    After this procedure has been carried out, we need to ensure that the film is produced to the desired thickness and quality, with no other issues. If everything is right, we need to return to stage one and reproduce the roll of polythene film with the remaining pellets.



       3. Cutting Bag Process

    The next procedure is to cut the polythene film into the desired sizes needed for the mailbags.

    • Rolls of film are cut using a heated blade. This melts the film and in turn seals the edges of the bags to the right size.
    • If the blade is not hot enough, it can lead to the edges splitting when being packed.
    • If the blade has not been replaced for a long period of time, it can also cause a problem with uneven edges due to its bluntness.

    Therefore in order for these issues to be reduced, we have adapted a list of quality control procedures to be undertaken after each stage.

    If all is well, then this is repeated with all of the rolls of material. The bags are now ready to be packed into small packets.


       4. Packing Process

    Once the bags have been cut to the right sizes, they are packed into packets of 100 pieces. However, before the packing takes place, we ensure that the machine has been set to 100 pieces to reduce the possibility of having a different quantity.



       5. Final Quality Check

    Once the bags are packed into packets of 100, they are ready to be placed into boxes with the size of mailbag determining the quantity per box. We then run through one more quality check before placing the full boxes onto the pallet ready to be shipped.


       6. Shipping

    Once all quality control has been carried out, the boxes are ready to be loaded onto the pallets and ready to be dispatched onto a container and shipped to the UK. The shipping process can take up to one month. Once the container arrives, we are ready to unload and the products are ready for sale.