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The Gaia Process

The Gaia Polypropylene bag begins life as PP Yarn Grade. These are tiny clear colored polygonal granules that are sent to extrusion.

In Extrusion, the PP Yarn granules along with any pigment or stabilizers (as per customer specification), is passed through an extruder with multiple-barrel temperature control zones.

The mixture passes through a screen pack, breaker plate, adaptor, and die. Good temperature control in each of these areas is meticulously maintained to perfect the first output of the extrusion process, the solid sheet.

In solid sheet extrusion, the polymer is melted and mixed in the extruder, then pushed through a die of a customizable opening. The die opening is matched to customer specification. This is accomplished by pulling the molten polymer from the die over cooling rolls and a sheet is extracted to the following take-up station.

This take-up station cuts the sheet into tape, this tape is stretched and shaped to match specification over a series of rollers.

The resulting tape is sent to State-of-the-art looms, with unparalleled efficiency to create spools of woven fabric.

Taking spools of this fabric we now add any filters and coatings pertinent to the customers at this stage. The filters are multi-purpose and multi-faceted. such as PP. Coating Grade, LDPE, or UV coating, any lamination etc.

This process is so customizable; Gaia bags can match virtually any existing specification. Once the coating is applied, the fabric is ready for printing.

The printing process, much like all of Syntronics is an industry leading process. The printing can be done for both AD*Star bags as well as traditional bags. AD*Bags are printed using another Starlinger mechanism that ensures quality for every single bag that it prints through runtime photographs. The final result is precise down to the last micron and can accommodate any design.

The bag is then sent to another state-of-the-art assembling where the bags are hermetically sealed, ensuring incredible tensile strength without the need for any potentially harmful glue.

Despite each station being tested for quality output, the final station is for final check after which the bags are sealed and made ready for shipping.