How Woven Fabric is Made: From Plastic Granules to Woven Tarp

Raw Material Heating and Extrusion (HDPE / PP)

Production starts from plastic granules, usually HDPE or PP.

Material goes into extruder, gets heated and melted, then pushed out through die head.
At this moment, it becomes a continuous plastic sheet.

What we control here:

• temperature stability
• melt uniformity
• sheet thickness

If this step is not stable, later it’s hard to fix. You may see uneven thickness or weak spots.

Tape Stretching (Key for Strength)

The sheet is not used directly. It needs to be stretched.

Stretching changes the internal structure and increases tensile strength.

Main points here:

• stretching ratio
• temperature zone
• cooling process

Not enough stretching → low strength
Too much → tape becomes brittle

Slitting into Flat Tapes

After stretching, the sheet is cut into flat tapes.

These tapes are what we use for weaving.

Important points:

• uniform width
• clean edges
• no cracks or broken lines

If tapes are not stable, even high density weaving will not give good result.

Winding (Tape Rolls)

The tapes are then wound into rolls.

All rolls are arranged and sent to circular weaving workshop.

We try to keep:

• stable tension
• clean winding
• no mixing or tangling

Otherwise, it will affect weaving stability.

Machine Setup Before Weaving

Before weaving starts, machine setup takes time.

Based on customer requirement, we adjust:

• number of tapes (warp setup)
• weaving density (warp & weft)
• loom size ring (final width)

This part is often ignored, but actually very important.

For some custom orders, machine adjustment may take several days.
If setup is not correct, problems will continue during production.

Circular Weaving Process

Now the main step — weaving.

Circular loom runs at high speed, interlacing tapes into a tubular woven fabric.

At this stage, we decide:

• density
• structure
• load strength

Higher density → stronger, but higher cost
Lower density → lighter, cheaper, shorter lifetime

Cutting the Tubular Fabric

Because the fabric comes out as a tube,

there is a blade installed on top of machine to cut it open.

After cutting, it becomes flat woven fabric.

We need to make sure:

• straight cut
• no tearing
• clean edges

Fabric Rolling

After cutting, fabric is rolled into big rolls.

At this point, it is already woven fabric, semi-finished product.
Some customers use it directly.

Double Side Lamination (For Woven Tarp / Greenhouse Use)

For applications like:

• woven tarp
• greenhouse woven film
• rain shelter

we usually do lamination.

PE coating is applied on both sides.

After lamination:

• waterproof
• stronger
• better for outdoor use

Simple Summary

Process is like this:

Raw material → extrusion → stretching → slitting → winding → weaving → cutting → lamination

Looks simple, but each step matters.

Final Note (Soft Call to Action)

If you are working on woven fabric, woven tarp, or greenhouse woven film,
you can share your application with us.

Different use needs different setup — density, gsm, lamination or not.

We have experience with:

• woven tarpaulin
• agricultural greenhouse woven film
• orchard rain shelter
• woven weed control fabric
• livestock curtain

If needed, we can check together and suggest a more suitable option.