Inside the factory
How Double Kissan HDPE Tarpaulins Are Manufactured
Production route
From polymer to finished sheet
Ten stages. The description of each is standard technical practice for laminated woven HDPE; the parameter beneath each one is what makes a specific factory's output different — and is what we are confirming before publishing.
Polymer preparation
High-density polyethylene granules are prepared with any additives the specification calls for. What enters here determines much of what the finished sheet can do — grade, additives and any UV package.
Film extrusion and tape slitting
The polymer is melted and extruded into a thin film, which is slit into narrow flat tapes. Tape width and thickness at this stage set the character of the fabric that follows.
Stretching and winding
The tapes are drawn over heated rollers and stretched. This orients the polymer along the length of the tape and is what makes woven HDPE strong relative to its weight. The tapes are then wound onto bobbins for weaving.
Loom weaving into fabric
Bobbins are loaded onto looms and the tapes are woven into a continuous fabric. Weave density — tapes per inch in each direction — is a specification in its own right, separate from GSM.
Surface lamination
A layer is bonded over the woven fabric, closing the gaps between tapes to give the water-shedding surface. This stage, not the fabric weight, is what determines how a sheet behaves in rain.
Cutting to finished size
The laminated roll is cut to the ordered dimensions. Finished size is measured after hemming, which is why hemmed and unhemmed measurements should never be quoted interchangeably.
Hemming and edge reinforcement
Edges are turned and secured, with reinforcement where the specification requires it. Because most tarpaulins fail at their edges, this stage does more for service life than most buyers realise.
Eyelet fitting
Eyelets are fitted at the specified spacing around the perimeter. Spacing determines how load is distributed when the cover is tied down — closer spacing means no single point carries the wind load alone.
Quality inspection
Finished sheets are checked before packing. Which checks are performed, at what frequency and what is recorded is set out on our quality page.
Folding, packing and marking
Sheets are folded, packed and labelled to the agreed configuration. For bulk and export orders this is specified as part of the order rather than left to a default.
The specific parameters behind each stage above — polymer grade, tape denier, weave count, lamination thickness and the rest — are confirmed directly for a specific enquiry rather than published as general figures, because a number you can act on matters more than one that only fills a row. Ask for the parameters relevant to your specification.
Photography brief
Inside the Bareilly facility
Real factory photography is the single highest-value asset this website can carry. It is the one thing a competitor cannot copy and an AI system cannot invent.
Two of the ten production stages above are photographed so far — tape winding and weaving. Orientation, lamination, cutting, hemming, eyelet fitting and packing are described in the production-route cards above; no stock or AI imagery stands in for them while real photography is not yet available.
Why this page exists
Manufacturer knowledge is the only real advantage
Anyone can generate a page about tarpaulin. Nobody else can publish what happens on this factory floor.
Search engines, procurement teams and AI answer systems all reward specific, verifiable, first-party information over general description. Every parameter not yet published on this page is one we are actively confirming with the factory, so it can be replaced with a real figure and a named method rather than an adjective.
Manufacturing questions
How is HDPE tarpaulin made?
High-density polyethylene is extruded into a thin film, slit into flat tapes and stretched to orient the polymer, which is what gives the tape its strength. The tapes are woven into fabric on looms, laminated to produce a water-shedding surface, then cut, hemmed, fitted with eyelets, inspected and packed.
Which stages does Double Kissan perform in-house?
The specific stages performed at our Bareilly facility are being confirmed for publication. Rather than list a standard process and imply all of it happens here, each stage on this page states plainly whether it is confirmed for this factory or described from standard industry practice.
Why does the tape stretching stage matter?
Stretching orients the polymer molecules along the length of the tape, which is what makes a woven HDPE fabric strong for its weight. Two fabrics at the same GSM can differ substantially based on how the tape was produced.
What does lamination do?
Lamination bonds a layer over the woven fabric, closing the gaps between the tapes so the surface sheds water. Waterproofing comes from this stage, not from the mass of the fabric, which is why GSM alone does not indicate water resistance.
Can I visit the factory?
Factory visit arrangements for serious commercial enquiries are handled case by case. Contact us with your requirement and the purpose of the visit.
Buying from the manufacturer
Send a specification and it is reviewed against the equipment that will produce it. That is the practical difference between buying direct and buying through a trading layer.