Scaling Up: How to Reach 500,000 Filter Bags per Year with Smart Automation
From Proven 200,000-Bag System to Large-Scale Intelligent Manufacturing
In the filter bag manufacturing industry, the ability to scale efficiently determines whether your factory leads or lags behind.
Many plants can reach 200,000 bags per year — but when order volumes double, inefficiency, labor costs, and unstable machines quickly become major bottlenecks.
KABORY’s smart automation platform provides a proven path to achieve 500,000 filter bags per year,
without doubling labor or sacrificing speed and reliability.
⚙️ Proven Scalability — From 200,000 to 500,000 Bags
Building on our verified 200,000-bag production layout, KABORY’s modular automation system can be seamlessly expanded.
Every process — from automatic cutting to snap band welding and sewing — remains synchronized at full speed.
Result: 2.5× higher annual output
Labor: only 1.6× increase (17 → 31 operators)
Speed: stable 10 m/min guaranteed for 5 + years
🧩 Modern 500,000 Bags/Year Production Layout
| Step | Equipment | Qty | Operator(s) |
|---|---|---|---|
| 1 | Filter Bag Needle Felt Slitter | 1 | 1 |
| 2 | Needle Felt Strip Slitter | 1 | 1 |
| 3 | Smart Cutter (Cuff / Disc / Layer) | 1 | 1 |
| 4 | Cuff-to-Snap Band Folding Machine | 2 | 2 |
| 5 | Automatic Snap Band Welding Machine | 1 | 1 |
| 6 | Automatic Filter Bag Sewing Machine | 4 | 4 |
| 7 | Profile Tape Gluing & Attaching Machine | 1 | 1 |
| 8 | Manual Sewing (Cuff + Bottom + Reinforcement Layer) | 20 | 20 |
| Total Direct Labor per Shift | — | 31 operators |
🧮 Traditional Factory Setup (for the Same 500,000-Bag Target)
| Step | Process | Operators (Traditional) |
|---|---|---|
| 1 | Filter Bag Needle Felt Slitter | 3 |
| 2 | Needle Felt Strip Slitter | 3 |
| 3 | Cuff / Disc / Layer Cutting (manual marking / template / die cutting) | 6 |
| 4 | Cuff-to-Snap Band Folding (manual flattening + insertion) | 4 |
| 5 | Snap Band Welding (≥ 2 punch presses + assistants) | 3 |
| 6 | Filter Bag Sewing (5 m/min, 8 machines required) | 8 |
| 7 | Profile Tape Gluing & Attaching (manual gluing + pressing) | 5 |
| 8 | Manual Sewing (Cuff + Bottom + Reinforcement Layer) | 20 |
| Total Labor per Shift | 52 workers |
📊 Labor Comparison — Traditional vs KABORY Smart Factory
| Metric | Traditional Factory | KABORY Smart Automation |
|---|---|---|
| Total Operators | 52 | 31 |
| Annual Output | 500,000 bags | 500,000 bags |
| Main Sewing Speed | 5 m/min (8 machines) | 10 m/min (4 machines) |
| Labor Reduction | — | − 40 % fewer workers |
| Productivity Increase | — | ≈ 2.3 × per capita |
| Energy & Maintenance Cost | High | Low |
| ROI Period | 18–24 months | < 12 months |
💡 Why Speed Integrity Matters
Many low-cost machines start at 7–8 m/min but drop to 5 m/min after only a few months — and never recover.
KABORY’s automatic filter bag sewing systems maintain 10 m/min operation for over 5 years, verified in U.S. and European factories.
That stability directly translates into:
- Consistent delivery schedules
- Fewer overtime hours and idle labor
- Predictable production planning
- Lower long-term costs
The difference between 5 m/min and 10 m/min is not just speed —
it’s the difference between keeping up and leading the market.
🤝 A Partnership for Every Stage of Growth
If you are a new manufacturer, joining KABORY gives you an instant cost advantage and faster route to market.
If you are an established producer, upgrading to KABORY automation lets you expand capacity without increasing headcount.
Whether your factory produces 200,000 or 500,000 filter bags per year,
KABORY guarantees stable 10 m/min speed, proven 5 + years — ensuring higher output, lower cost, and sustainable performance.