How to Calculate PP Woven Bag Cost and Jumbo Bag Cost | Worked Example
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How do you cost a PP woven sack or a jumbo bag (FIBC) correctly? In this 5-minute video we take a 50 kg laminated woven sack and a 1,000 kg U-panel FIBC and cost them step by step: how a woven sack is made, the mesh and denier formula for fabric GSM, fabric area and empty bag weight (capacity is not bag weight), cost per bag at the current virgin PP benchmark with material and conversion, what moves the price most, FIBC parts and weight, reconciling calculated vs weighed bag weight, safety factor and FIBC Types A, B, C and D, and the most common costing mistakes.
Best viewed on a TV or big screen.
Presented by Rajesh Modhvadia.
CHAPTERS
0:00 Intro
0:10 Also in Hindi
0:15 How a woven sack is made
0:33 Mesh, denier and GSM
0:55 Step 1: fabric area and weight
1:15 Step 2: total bag weight
1:35 Step 3: cost per bag
1:57 What moves the price
2:15 Inside an FIBC
2:35 Step 4: FIBC weight and cost
2:57 Capacity is not bag weight
3:15 Safety factor and FIBC types
3:35 Costing mistakes
3:49 Woven Sack & FIBC Calculator on GPN
4:03 Try it on GPN
4:15 Recap: 3 rules
4:29 Sponsor these videos
4:37 Thank you
KEY FORMULAS
Fabric GSM = (warp mesh + weft mesh) × denier ÷ 228.6 (mesh in tapes per inch, denier = grams per 9,000 m)
Fabric area of a tubular sack = 2 × flat width × cut length
Bag weight = fabric + lamination + thread (+ liner if any)
Cost per bag = material (with wastage) + conversion; selling price = cost × (1 + margin)
WORKED EXAMPLE 1: 50 kg laminated woven sack (illustrative Indian rates)
560 × 950 mm cut size, 10 × 10 mesh, 900 denier = 78.7 GSM · fabric 1.064 m² = 83.8 g · lamination 20 GSM = 21.3 g · thread 2 g · bag weight 107 g
Virgin PP ₹155/kg (15 Oct 2026 benchmark), lamination PP ₹155/kg, thread ₹180/kg, tape + weaving ₹22/kg, lamination ₹0.40, printing ₹0.40, cut and stitch ₹0.50 per bag, wastage 3%
Material ₹17.14 + conversion ₹3.14 = ₹20.29 + 10% margin = ₹22.32 per bag (₹22,315 per 1,000)
Each 1 GSM of fabric ≈ ₹0.21 per bag = ₹2.1 lakh on 10 lakh bags
Capacity is not bag weight: the 50 kg sack weighs 107 g empty - weigh 10 finished bags and reconcile (±3%)
WORKED EXAMPLE 2: 1,000 kg U-panel FIBC, 90 × 90 × 110 cm
Body 1,025 g + top skirt & fill spout 120 g + bottom spout 75 g + 4 loops 308 g + thread & ties 45 g + document pouch & label 27 g = 1.60 kg empty bag weight
Material ₹255 (₹155/kg + 3% wastage) + conversion ₹64 + stitching ₹60 + printing ₹10 = ₹389 + 12% margin = ₹436 per bag
Reconcile the BOM weight with weighed finished bags (avg of 5); if the difference is more than ±3%, fix the BOM before quoting
Safety factor: 5:1 single trip (5,000 kg test), 6:1 multi-trip (6,000 kg test) - ISO 21898 / IS 15723
Cost your own sacks and jumbo bags with the Woven Sack & FIBC Cost Calculator on GPN:
https://app.globalpackagingnetwork.com
Previous video: Self-adhesive Label Costing - https://youtu.be/Fffun-x5FTs
Hindi version of this video: https://youtu.be/wLNzicEftfE?si=tkdKk5qPTyoWpC9h
Want to sponsor these videos? Contact +91 96500 47650 (Rajesh Modhvadia)
Which bag do you make or buy - and at what GSM? Tell us in the comments.
Note: Virgin PP ₹155/kg is a provisional benchmark based on the 15 October 2026 Polymerupdate assessment - refresh it against your actual supplier invoice before every quotation cycle. Other rates and weights are illustrative Indian figures for learning; actual prices vary by supplier, quantity and specification. Always confirm FIBC designs with certified test reports.
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