State-of-the-Art Plant Infrastructure & Machinery
Operating precision PP Spunbond non-woven extrusion lines and downstream converting units in Madurai, Tamil Nadu. Designed for 100% GSM accuracy, superior mechanical strength, and seamless B2B roll converting.
Precision Multi-Beam Extrusion & Roll Finishing
Continuous filament extrusion, thermal calender point bonding, electronic slitting, and dust-controlled warehouse bays serving converters across South India.
Multi-Width Extrusion Lines & Embossing Patterns
Operating advanced PP Spunbond production lines ensuring 100% GSM accuracy and high-performance mechanical properties across all width variations.
Unit 1 — 1.6M Line
Shopping bags, D-cut/W-cut carry bags, rice sacks, and agricultural crop cover fleece.
Unit 2 — 2.3M Line
Mattress pocket spring encasements, furniture upholstery backing, sofa dust covers, and industrial liners.
Unit 3 & 4 — 3.2M High-Speed Lines
Broad-width surgical drapes, medical PPE, hygiene diaper leg cuffs, multi-lane automated converters, and master jumbo rolls.
Advanced Converting & Value-Addition Machinery
Equipped with precision machinery for customized slitting, rewinding, laminating, sheet cutting, bag making, and printing.
Precision Rewinding Machinery
Roll Weight, Core Calibration & Tension Optimization
Automated rewinding lines calibrate roll diameter, core alignment (76 mm / 3" & 152 mm / 6" heavy-duty cores), and uniform winding tension. Ensures compact, wrinkle-free roll profiles engineered for high-speed automated unwinding on converter lines without fabric jamming.
Max Diameter: 1,200 mm • Cores: 76 mm & 152 mm • Electronic Web Guide
High-Speed Slitting Machinery
Rotary Shear Multi-Knife Slitting from 50 mm to 3,200 mm
Equipped with multi-blade pneumatic rotary shear knives delivering clean, burr-free edge slitting across any custom width requirement. Operates with ultra-tight edge tolerances of ±1 mm to ±2 mm, ideal for narrow tape winding, diaper elastic cuffs, and custom bag widths.
Width Range: 50 mm to 3,200 mm • Slit Tolerance: ±1 mm • Dust Extraction
Automated Sheet Cutting Equipment
Clean Non-Fraying Edge Cross-Cutting for Flat Sheets
Computerized rotary cross-cutters and guillotine sheet machines delivering uniform, square-cut flat non-woven sheets. Eliminates edge fraying and delivers ready-to-use panels for mattress multi-needle quilting, hospital bedsheets, surgical examination drapes, and agricultural frost blankets.
Custom Lengths & Widths • 100% Square-Cut Edges • Stack Counting
Extrusion Lamination & Film Coating
Multi-Layer Barrier Composites & Value Addition
Extrusion PE film coating and thermal composite lamination bonding Spunbond substrates with polyethylene film, breathable microporous film, or reverse-printed BOPP film. Produces 100% liquid-proof, blood-barrier, and high-burst materials for medical gowns and packaging.
Coating: 15 to 40 GSM • Substrates: PE Film, Breathable Film, BOPP • 100% Water Barrier
Automated Bag Conversion Machinery
High-Speed Ultrasonic Bag Making & Banana Sleeves
State-of-the-art automated bag converting machines transforming Spunbond rolls into finished eco-friendly bags with ultrasonic welded seams. Produces W-cut grocery carry bags, D-cut boutique totes, 3D box gusseted bags, loop-handle bags, and agricultural banana bunch covers.
Designs: W-Cut, D-Cut, 3D Box, Loop Handle • Ultrasonic Sealing • High-Burst Seams
Advanced Industrial Printing Technologies
Flexographic (Up to 6 Colors) & Rotogravure Printing
Integrated printing units providing vibrant, high-definition graphics on non-woven fabrics. Flexographic printing delivers high-speed roll-to-roll branding (up to 6 colors), while Rotogravure printing provides photorealistic, multicolor finishes for branded retail and BOPP packaging.
Flexo: Up to 6 Colors • Rotogravure: Photorealistic Multi-Color • Food-Safe Inks
Dual Printing Technologies for Vibrant Branding
Whether you require high-speed continuous logos on shopping bag rolls or photorealistic multicolor art for luxury consumer packaging, our in-line printing facilities deliver sharp, smudge-free adhesion.
Flexographic Printing (Up to 6 Colors)
High-speed, cost-effective roll-to-roll printing optimized for retail shopping bags, carry totes, and recurring corporate logos with fast changeover times.
Rotogravure Multicolor Printing
Ultra-precise cylinder engraving delivering photographic quality, vibrant gradients, and fine multi-color registration on BOPP-laminated packaging and rice sacks.
Technical Printing Parameters
- Corona Surface Treatment: Inline corona treatment boosting dyne levels to ensure crisp ink retention without peeling.
- Food-Contact Safe Inks: Environmentally friendly, low-VOC water-based and alcohol-based inks compliant with food packaging standards.
- Full Roll Width Printing: Capable of printing across varied roll widths from 200 mm up to 1,600 mm width runs.
- Zero Smudge Drying: Controlled infrared and forced hot-air drying chambers guaranteeing completely cured rolls.
Own Transportation & Seamless Line-Haul Logistics
Our efficient in-house logistics system and dedicated vehicle fleet guarantee timely, damage-free domestic deliveries across Tamil Nadu, Karnataka, Kerala, Andhra Pradesh, and Telangana directly from our Madurai production plant.
Plant Machinery & Capability Specifications
Engineering parameters maintained at Thusmaa Madurai production facility.
| Machinery / Capability | Operational Parameters & Value Addition |
|---|---|
| Extrusion Line Widths | 1.6M (58-63"), 2.3M (85-90"), and 3.2M (115-126") Multi-Beam Units |
| Embossing Calender Profiles | Big Dot, Medium Dot, Small Dot, Oval, and Diamond Point Bonding |
| Fabric Basis Weight | 10 GSM to 150 GSM (100% GSM consistency across all width variations) |
| Slitting Capability | Precision rotary multi-blade slitting from 50 mm micro-tapes up to 3,200 mm broad rolls (Tolerance: ±1 mm) |
| Rewinding Cores | Standard 76 mm (3 inch) and 152 mm (6 inch) reinforced cardboard cores with automated web guide |
| Sheet Cutting Units | Cross-cutting guillotine delivering flat, square-cut non-fraying sheets for mattress panels & medical covers |
| Lamination & Coating | Extrusion PE coating (15–40 GSM), breathable microporous film, and BOPP lamination for 100% liquid barrier |
| Bag Conversion | High-speed automated lines for W-cut, D-cut, 3D box bags, loop handles, and banana bunch sleeves |
| Printing Technologies | Flexographic (up to 6 colors) for rolls; Rotogravure for photographic multi-color retail branding |
| Transportation & Logistics | In-house dedicated fleet delivering direct line-haul across Tamil Nadu, Karnataka, Kerala, Andhra Pradesh & Telangana |
Need customized slit widths, lamination, or printed rolls for your converting line?
Connect directly with our Madurai manufacturing and technical operations team.