What Is a Complete Production Line?
A complete cement bag production line is a set of integrated machines that together convert raw materials into finished bags ready for filling at cement plants. Instead of buying individual machines and assembling a line, complete production lines are engineered to work together with matched speeds, material handling, and quality systems.
There are three main types of complete lines:
- Paper Valve Sack Line — Tuber + Bottomer (+ optional printer)
- PP Woven Bag Line — Extruder + Looms + Laminator + Printer + Cutter + Sewer
- FFS System — Form-Fill-Seal machine (self-contained)
Three Production Line Types at a Glance
Paper Valve Sack Production Lines
Paper valve sack lines are the global standard for cement bag production, especially in Europe, Middle East, and the Americas.
Components
| Machine | Function | Price Range |
|---|---|---|
| Tuber | Forms paper sheets into tubes | $45,000–$250,000 |
| Bottomer | Folds bottom, inserts valve | $40,000–$220,000 |
| Flexo Printer* | Prints branding (if not inline) | $15,000–$90,000 |
| Conveyor System | Connects machines | $5,000–$15,000 |
| Total | — | $105,000–$575,000 |
*Some tubers include inline printing, eliminating the need for a separate printer.
Top Paper Lines Compared
TECON Basic Line (TC-LINE-100)
- Speed: 80–120 bags/min
- Layers: 2–4
- Printing: 4-color inline
- Components: TC-T100 Tuber + TC-B100 Bottomer
- Price: $85,000–$160,000
- Best for: New factories, medium-scale production, developing markets
TECON Premium Line (TC-LINE-300)
- Speed: 150–300 bags/min
- Layers: 2–5
- Printing: 8-color inline
- Features: AI quality detection, PE film layer, chemical adhesive, reinforcement
- Components: TC-T300 Tuber + TC-B300 Bottomer
- Price: $220,000–$470,000
- Best for: Large factories, export markets, premium production
YOUNIKER Complete Line (YK-LINE-200)
- Speed: 100–150 bags/min
- Layers: 2–4
- Printing: 4-color
- Features: Digital cutting, quick changeover, both-end pasting
- Components: ZT1962S Tuber + HD8916 Bottomer
- Price: $120,000–$220,000
- Best for: Growing businesses, multi-product factories
PP Woven Bag Production Lines
PP woven lines are dominant in India, Southeast Asia, and Africa. They require more machines but produce versatile, moisture-resistant bags.
Components
| Machine | Quantity | Function | Price Range |
|---|---|---|---|
| Extruder | 1 | PP granules → flat tape | $25,000–$80,000 |
| Circular Loom | 4–12 | Weave PP tape into fabric | $15,000–$55,000 each |
| Laminator* | 1 | Add PE/BOPP film layer | $20,000–$45,000 |
| Flexo Printer | 1 | Print branding on fabric | $15,000–$60,000 |
| Cutting Machine | 1 | Cut fabric to bag length | $8,000–$18,000 |
| Sewing Line | 1 | Close bag bottom/top | $5,000–$15,000 |
| Total (8 looms) | — | — | $200,000–$500,000 |
*Lamination is optional but recommended for moisture-prone markets.
Top PP Woven Lines Compared
Five Fingers Valve Bag Line
- Type: PP woven valve bags
- Speed: 30–40 bags/min
- Origin: India
- Price: $42,000–$55,000 (valve machine only; full line $150,000–$300,000)
- Best for: Indian market, Africa, PP valve bag demand
FOR DAH FD-900 Multi-Wall Line
- Type: Multi-material (paper + PP + PE)
- Speed: 40–80 bags/min
- Layers: Up to 6-ply
- Origin: Taiwan
- Price: $150,000–$350,000
- Best for: Premium multi-material bags, export markets
Budget Startup PP Line
- Components: 4 looms + basic extruder + manual cutting + sewing
- Speed: 150,000–300,000 bags/month
- Price: $80,000–$150,000
- Best for: New factories in developing markets
FFS Production Systems
FFS (Form-Fill-Seal) is the most advanced and most automated cement packaging method.
Components
| Machine | Function | Price Range |
|---|---|---|
| FFS Machine | Forms, fills, and seals bags | $80,000–$200,000 |
| Weighing System | Precise cement dosing | $15,000–$40,000 |
| Conveyor | Bag transport | $10,000–$25,000 |
| Palletizer* | Automatic bag stacking | $30,000–$80,000 |
| Total | — | $135,000–$345,000 |
Advantages
- Lowest labor cost per bag
- Dust-free operation
- Lowest material cost per bag ($0.05–$0.08 vs $0.10–$0.25 for paper)
- Highest consistency
Complete Line Comparison
| Feature | Paper Valve Sack | PP Woven | FFS |
|---|---|---|---|
| Investment | $105K–$575K | $200K–$500K | $135K–$345K |
| Speed | 80–300 bags/min | 30–80 bags/min | 400–800 bags/hr |
| Labor Needed | 2–4 operators | 4–10 operators | 1–2 operators |
| Material Cost/Bag | $0.10–$0.25 | $0.08–$0.15 | $0.05–$0.08 |
| Bag Quality | High (print) | Good (durable) | Good (sealed) |
| Dust Level | Low | Moderate | Near Zero |
| Popular Regions | Europe, Middle East | Asia, Africa | Europe, Americas |
| Flexibility | Moderate | High | Low |
ROI Analysis
Paper Line — TECON Basic (TC-LINE-100)
- Investment: $130,000
- Monthly output: ~1,000,000 bags @ $0.06 profit/bag = $60,000 revenue
- Operating costs: ~$35,000/month (materials, labor, energy)
- Net monthly profit: ~$25,000
- Payback period: ~5–6 months
PP Woven Line — 8-Loom Setup
- Investment: $280,000
- Monthly output: ~1,000,000 bags @ $0.04 profit/bag = $40,000 revenue
- Operating costs: ~$25,000/month
- Net monthly profit: ~$15,000
- Payback period: ~18–19 months
How to Choose Your Line
Decision Tree
-
What bag type does your market require?
- Paper valve sacks → Paper line
- PP woven bags → PP woven line
- PE sealed bags → FFS system
-
What is your budget?
- Under $100,000 → Budget PP woven or semi-auto paper
- $100,000–$300,000 → Mid-range paper or standard PP woven
- Over $300,000 → Premium paper, large PP woven, or FFS
-
What is your target volume?
- Under 500,000 bags/month → Small line
- 500,000–2,000,000 bags/month → Medium line
- Over 2,000,000 bags/month → Large line or multiple lines
-
What is your market location?
- Europe/Americas → Paper valve sack or FFS
- Asia → PP woven (dominant) or paper
- Africa → PP woven (growing) or budget paper
- Middle East → Paper valve sack or FFS
Factory Space Requirements
| Line Type | Minimum Space | Recommended Space |
|---|---|---|
| Paper Basic Line | 200 m² | 400 m² |
| Paper Premium Line | 400 m² | 800 m² |
| PP Woven (8 looms) | 800 m² | 1,500 m² |
| FFS System | 100 m² | 250 m² |
Frequently Asked Questions
Can I start small and expand later? Yes. Paper lines can be upgraded from basic to premium models. PP woven lines can add looms incrementally. However, planning for expansion from the start (in terms of factory space and electrical capacity) is recommended.
Should I buy from one brand or mix brands? Single-brand lines offer better integration, warranty coverage, and technical support. Mixed-brand lines can save money but may have compatibility issues and split responsibility for problems.
What utilities do I need?
- Electricity: 3-phase power, 50–200 kW capacity depending on line size
- Compressed air: 500–2000 L/min at 6–8 bar
- Water: For cooling systems (especially PP extrusion and lamination)
- Adhesive/ink storage: Temperature-controlled area
What is the delivery and installation timeline? Typically 3–6 months from order to production-ready: 30–90 days manufacturing, 30–45 days shipping, 15–30 days installation and commissioning.
Use our Cost Calculator to estimate your production costs or the ROI Calculator to plan your investment. Browse all available machines in the machine directory.