High Density Polyethylene Eyeleted Tarpaulins as packaging for fruits and vegetables

Agriculture is Indian economy�s mainstay and it comprises 18.5% of the gross domestic product (GDP). In the last two years agriculture growth rate has been 4% against growth rate of 2.5% during the 10th Five Year Plan. 4.1% growth implies a Rs 1,50,000 crore increase in Agriculture GDP. India is the leading producer of coconuts, mangoes, milk, bananas, dairy products, ginger, turmeric, cashew nuts, pulses and black pepper. It is also the second largest producer of rice, wheat, sugar, cotton, fruits & vegetables. The most important area for investment in agriculture relates to the provision of water and its most efficient use. About 16 mln hectares is expected to be added to the irrigated area during the 11th Five-Year Plan. An assessment of the irrigation system in India indicates that efficiencies of surface water systems can be improved from the present level of 35-40% to about 60% and that of groundwater systems from 65% to about 75%. Moreover, about 84% of the created irrigation potential has been utilised in India. Efficient use of crop water can increase the gross irrigated area. Plastics in agriculture has been growing at a fast pace. Plastic products retain moisture levels in the soil by the use of plastic products such as LLDPE mulch film.
Agriculture GDP

(Source : Reserve Bank of India , Planning Commission Targets)

(Source : Reserve Bank of India, Planning Commission Targets)

Plastics in Agribusiness : Plastics to a common man was earlier only a high density polyethylene bucket or bag, but with its versatile nature, it has grown to numerous plastic products in several sectors including Agribusiness. Plastic products related to agriculture include LLDPE Mulch film, PVC pipes, HDPE Pipes, LLDPE Drip Irrigation Pipes, HDPE Agrishade Nets, PE Greenhouse etc would lead to higher productivity (yield) through efficient use of water, fertilizers.
New Products to be Adopted in Plasticulture:
• HDPE Eyeleted Tarpaulins as sacks for fruits and vegetables
• LDPE Reverse Printed Extrusion Coating on 2 sides of HDPE Woven Sacks
Plastics could be defined as most �Able� material to increase the productivity of fruits and vegetables for farmers leading to huge savings. Plastic pipes in agriculture have resulted in huge savings for the farmers. Plastics have grown from films to agrishade nets, from tapes to agrishade nets and from monofilament to monofilament agrishade nets.
India being No.2 producer of fruits (50 mln tons) and No.3 producer of vegetables (90 mln tons) in the world, high potential exists for usage of plastic products in agriculture.
Tarpaulin is a plastic product made up of woven HDPE fabric laminated with LDPE, LLDPE or a blend of two. Tarpaulin, which is also known as �talpatri� brings in numerous enduses in agriculture and infrastructure sectors, as well as chemical industry, petrochemical industry and fertilizer industry. The consumption of HDPE Tarpaulin in 2009-10 in India was 30,000 Tons.
Advantages of HDPE Tarpaulin
• It is light in weight
• Handling is easy
• Water proof, does not get wet or soaked, mildew and rot resistant
• Can be manufactured in desired colours
• Printing is much more attractive
• Tough and long lasting
• Resistant to scratches
The design process of polyethylene tarpaulins consists, cross weaving of poly yarn followed by double-sided lamination. Thus, it is possible to make tight or loose tarpaulin designs according to the purpose for which tarpaulins are designed. A tight pattern can be recognized by the high number of cross weaves per inch, which leads to higher durability and resistance to external factors. Polyethylene tarpaulins are resistant to weather variations. It is possible to get polyethylene tarpaulins that stand sturdy even during heavy rains without sagging.
Manufacturing Process
LAMINATION: HDPE fabric is laminated with LDPE, LLDPE or a blend of the two. It could be a three-layer tarpaulin having one layer of woven fabric and two layers of LDPE/LLDPE coating, one each on either sides. 5 layer tarpaulins consisting of two layers of woven fabric sandwiched between layers of LDPE/LLDPE coating are also made. SEALING: The laminated fabric, which is normally 48 inches wide, is cut into pieces according to desired size and sealed.
BORDER MAKING: A border is made and a rope is provided along the border to provide strength. Metallic loops are used to make eyelets along the border, through which the tightening ropes, are passed.
Machinery
A tape extruder, a lamination machine and eyeleting machines are used for manufacturing high density polyethylene tarpaulins. HDPE Tarpaulin is manufactured on a tape extruder. HDPE Agrishade Nets, HDPE Raschel bags and HDPE Woven Sacks for fertilizer packaging can be manufactured on this tape extruder.
End Uses of HDPE tarpaulin
Transportation
During the rainy season, HDPE tarpaulin is used for covering of trucks, which is a major market at present.
Storage
This is the second largest market which includes covers for Godowns, for crops, Mandaps, temporary sheds and out-door open storage.

HDPE Eyeleted Tarpaulins as Sacks for Fruits & Vegetables for Entrepreneurs:
Tape extrusion process gives an entrepreneur a flexibility to produce HDPE woven sacks, HDPE tarpaulins and many more products such as HDPE agrishade nets and HDPE Raschel bags on the same tape extruder.
Plastics, a gain to the society by its waterproof characteristic has been a gain to the existing processors of woven sacks by an increase in a product mix, capacity utilization, average selling price and thus increase in net profitability.
HDPE Tarpaulin is a packaging material that offers ventilation to fruits and vegetables allowing more breathability because of increased ventilation. Specifications of HDPE Eyeleted Tarpaulins as sacks for packaging of fruits & vegetables with more number of eyelets for breathability: 600 Denier, 7 mesh with filler of 15-20%. Weight of HDPE Eyeleted tarpaulin as sack �25 kg - 65 gms, 50 kg -125 gms (Present Prevailing Prices, subject to changes). Its waterproof characteristic prevents the fruits & vegetables from getting rotten during rainy season.
• New Jute bag � 25 kgs (24*36 inches)-Rs12, 50 kgs (30*50 inches)-Rs 18
• Old Jute bag � 25 kg � Rs 3.5, 50 kg � Rs 6
• PP Leno bag- 25 kg-Rs 4.5 & 50 kg -Rs 6.5
• HDPE Eyeleted Tarpaulin as sack � 25 kg- Rs 7, 50 kg � Rs 14 (longer shelf life, can be reused many times in comparison to PP Leno bags & Jute bags)
Eyeleting machines are available locally. 28 number eyeleting machine of outer diameter 23 mm and inner diameter 11.5 mm are available with an automatic eyeleting machine price of Rs 1.5 lacs. Average price of Aluminium eyelets for 144 nos is Rs 60.
• Potential � 364,000 tpa for use in Agriculture in India where Fruit production is 50 mln tons, Vegetable production is 90 mln tons. The existing packaging materials are Jute, PP Leno bags

With only an additional investment in the eyeleting machines, would lead to a new product for the woven sack industry. Manufacturers of HDPE tarpaulins need no additional investment. Accelerating the process of a market penetration of this new product would occur with an involvement of commission agents. Commission agents are people who know the local language, whom the farmers have faith in and who can communicate effectively the benefits of plastic products related to agribusiness to the farmers. Branding of farm produce to distinguish a good quality produce with the help of 2 side lamination on a sack as high density polyethylene tarpaulin which could include the name of the farmer would lead to the delivery of good quality produce for wholesaler to retailer.
(Author: Ms Poorvi C. Desai, Sr. Manager, Business Development � Polymers, Reliance Industries Ltd)