30 Six-Shuttle Circular Looms Commissioned at Philippine Rice Mill — Thread Breakage Down 80%

Project Summary

Image: Circular loom in operation or multiple machines running in formation.

Project Overview

Image: HAOSEN engineers with the customer in front of the successfully installed and commissioned circular looms.

A leading rice processor in the Philippines has commissioned 30 high-speed six-shuttle circular looms and one fully automatic cutting-sewing-inserting-hemming machine from HAOSEN, replacing aging equipment that had constrained output and bag quality for years.

The mill produces hundreds of thousands of tons of rice annually and requires woven sacks that can withstand high-speed filling, stacking, and transportation without failure.

The customer came to HAOSEN with two persistent problems that their previous equipment could not resolve.

First, inconsistent flat yarn tensile strength was causing frequent warp breakage on the looms. Every broken thread resulted in machine downtime, fabric waste, and lost production time.

Second, the existing hemming equipment produced uneven bag mouths and inaccurate spout insertion, slowing down the filling line and compromising the seal quality of finished sacks.

After an on-site assessment and detailed discussion of the customer's bag specifications, HAOSEN engineers developed a targeted production solution.

Customized Production Solution

Extrusion Parameter Optimization

PP resin ratio, stretching temperature, and draw ratio were carefully calibrated to produce flat yarn with consistent tensile strength, addressing the root cause of loom breakage.

Floating-Roller Dual-Roller Design

The 30 six-shuttle looms were equipped with a dual floating-roller system and automatic warp tension balancing. The design reduces friction between the tape and guides while maintaining a flat and uniform fabric surface.

Vision-Guided Cutting, Sewing, Inserting & Hemming

The automatic machine was equipped with a high-precision visual inspection system and a German-imported deviation correction unit. This ensures accurate bag positioning and clean, consistent hemming on every sack.

Bluetooth-Enabled Monitoring

Wireless sensors transmit real-time production data and fault alerts, allowing mill management to monitor line status remotely without being on the factory floor.

Installation, Commissioning & Training

HAOSEN engineers remained on site for two weeks to install and commission all 31 machines and provide structured hands-on training for the customer's operating and maintenance teams.

Following successful commissioning, the equipment entered full production. Engineers from both sides marked the completion of the project with a group photo in front of the running looms.

Project Results

The upgraded production line delivered measurable improvements in both equipment performance and bag quality.

• 80%+ reduction in thread breakage

• More consistent fabric quality

• Improved bag mouth uniformity

• Better downstream filling-line efficiency

• 31 machines successfully installed and commissioned

• 2 weeks of on-site training and technical support

The customer reports that thread breakage has dropped by more than 80% compared with the previous machines, while fabric consistency and bag mouth uniformity have significantly improved.

Customer Feedback

Image: Group photo with the customer or circular loom equipment in operation.

“HAOSEN did not just sell us machines — they identified why our yarn kept breaking and why our bag mouths were uneven, then fixed both. The 80% reduction in breakage alone has paid back the investment in downtime saved. We look forward to continuing this partnership.”

— Plant Manager, Philippine Rice Processing Enterprise

About the Equipment

Image: Circular loom details or equipment running in production.

High-Speed Six-Shuttle Circular Loom

• Six-shuttle configuration for high-output tubular fabric production

• Floating-roller dual-roller design to reduce friction and warp breakage

• Warp tension balancer for consistent fabric flatness

• Bluetooth wireless sensors for remote monitoring and fault alerts

Automatic Cutting-Sewing-Inserting-Hemming Machine

• Integrates cutting, sewing, spout insertion, and hemming in one machine

• High-precision visual inspection system

• German-imported deviation correction system for accurate bag positioning

• Even bag mouths for improved downstream filling efficiency

About HAOSEN

HAOSEN (Hebei Haosen Leituo Machinery Technology Co., Ltd.) is a Chinese manufacturer and turnkey supplier of PP/PE woven bag production lines, FIBC bulk bag lines, spout pouch sealing and filling lines, and dunnage air bag lines.

Since 2008, HAOSEN has delivered complete production lines to customers in over 30 countries, combining in-house manufactured core equipment with a vetted partner network, on-site engineering, and structured training.