Sisal Decortication, Bast Fiber Spinning, Woven PP Bag & Twine Manufacturing ERP: Leaf Weighbridge Intake, Brush-Drum Fiber Grade (UG/SSUG) Yield, Circular Loom Weft Telemetry & Export Bale Traceability

Commercial sisal plantations, bast-fiber spinning mills, cordage factories, and woven polypropylene (WPP) agro-packaging plants across Taita-Taveta (Voi, Taveta, Mwatate), Kilifi, Kwale, Mogotio, Nakuru, and Machakos operate dual agricultural and high-speed industrial production lines. Managing field leaf cutting, corona wet decortication, sun-drying lines, brushing machines, gill-box sliver drawing, baler presses, and circular PP tape looms on disconnected spreadsheets leads to inflated cutter task-rate payrolls, untracked wet-to-dry fiber recovery shrinkage, misclassified export grades (3L vs. UG vs. Tow), unmonitored circular loom warp/weft yarn breakages, and shipping-line container weight discrepancies on 250 kg high-density bales.

At devManue, we engineer custom Sisal Decortication, Cordage Spinning & Woven Packaging ERP platforms that unify GIS estate block cutter piece-work, RS-232 tractor-trailer leaf weighbridges, decorticator water/flume effluent recovery, brush-room grade yield accounting, spinning frame and circular loom OEE telemetry, and export phytosanitary/packing list documentation.

1. Estate Block Leaf Harvesting, Cutter Piece-Rate Biometrics & Wet Decortication Mass-Balance

Sisal leaves (Agave sisalana and hybrid H.11648) contain only 3.2% to 4.5% extractable dry structural fiber by green leaf weight, and must be decorticated within 24 to 48 hours of cutting before leaf juices oxidize and stain the fiber.

• GIS Plantation Sub-Block Cycle & Leaf-Length Grading: Maps every estate field block by planting year, hybrid clone variety, cutting cycle (first cut at 30–36 months through seventh cut before bole/poling), and leaf length classification (Long ≥90 cm vs. Short 60–89 cm).
• Cutter Bundle Tallying & Biometric Piece-Work Payroll: Field supervisors scan cutter ID badges on offline Android devices to record daily task bundles (typically 1,500 to 2,500 leaves per task stacked in bundles of 25 or 30), automatically cross-checking field bundle counts against trailer weighbridge net green-leaf weight at the factory gate.
• Corona Decorticator Throughput & Flume Tow Recovery: Tracks green leaf tonnage fed into the decorticator feed chains, wash-water flow rates, primary line fiber wet output, and flume-tow recovery from decortication waste pulp before sun-drying on drying wires.
• Sun-Drying Line Moisture Gating & Brush-Drum Grade Sorting: Prevents premature brushing of damp fiber (>13% moisture) and tracks brush-room sorting yields across statutory East African sisal grades: Grade 1, Grade 3L (Long), Grade 3S (Short), UG (Under Grade), SSUG (Sub-Standard Under Grade), Tow 1, and Tow 2.

2. Decortication Recovery, Brush-Room Grade Yield & Circular Loom OEE Engine

Whether exporting raw brushed sisal bales to international pulp/specialty paper and composite buyers or converting fiber and polypropylene raffia tape in-house into agricultural baler twine, ropes, gunny sacks, and laminated WPP bags, plant directors require exact mass-balance visibility from green leaf and polymer resin to finished goods:

from decimal import Decimal, ROUND_HALF_UP

class SisalDecorticationAndPackagingMassBalanceEngine:
    """
    Computes sisal green-leaf to dry brushed fiber recovery %, grade distribution
    (3L, UG, SSUG, Tow), baling press moisture compliance, and WPP circular loom yield.
    """
    @staticmethod
    def evaluate_shift_decortication_and_baling_batch(
        green_leaf_intake_kg: Decimal,
        expected_clone_fiber_yield_pct: Decimal,
        grade_3l_dry_kg: Decimal,
        grade_ug_dry_kg: Decimal,
        grade_ssug_dry_kg: Decimal,
        brushing_tow_dry_kg: Decimal,
        measured_bale_moisture_pct: Decimal,
        bales_pressed_count: int,
    ) -> dict:
        total_extractable_dry_fiber_kg = (
            grade_3l_dry_kg + grade_ug_dry_kg + grade_ssug_dry_kg + brushing_tow_dry_kg
        ).quantize(Decimal("0.01"), rounding=ROUND_HALF_UP)

        actual_fiber_recovery_pct = (
            (total_extractable_dry_fiber_kg / green_leaf_intake_kg) * Decimal("100.0")
            if green_leaf_intake_kg > Decimal("0")
            else Decimal("0.0")
        ).quantize(Decimal("0.01"), rounding=ROUND_HALF_UP)

        prime_line_fiber_share_pct = (
            ((grade_3l_dry_kg + grade_ug_dry_kg) / total_extractable_dry_fiber_kg) * Decimal("100.0")
            if total_extractable_dry_fiber_kg > Decimal("0")
            else Decimal("0.0")
        ).quantize(Decimal("0.01"), rounding=ROUND_HALF_UP)

        avg_bale_weight_kg = (
            total_extractable_dry_fiber_kg / Decimal(str(max(1, bales_pressed_count)))
        ).quantize(Decimal("0.01"), rounding=ROUND_HALF_UP)

        # Export sisal bales must not exceed 12.5% moisture to prevent spontaneous heating/rot in sea containers
        moisture_passed = measured_bale_moisture_pct <= Decimal("12.5")
        yield_variance_pct = (actual_fiber_recovery_pct - expected_clone_fiber_yield_pct).quantize(
            Decimal("0.01"), rounding=ROUND_HALF_UP
        )

        if moisture_passed and actual_fiber_recovery_pct >= (expected_clone_fiber_yield_pct - Decimal("0.40")):
            release_status = "APPROVED_FOR_250KG_HIGH_DENSITY_EXPORT_BALING"
        else:
            release_status = "HOLD_MOISTURE_OR_DECORTICATION_DRUM_CLEARANCE_ALERT"

        return {
            "green_leaf_intake_kg": green_leaf_intake_kg,
            "total_dry_fiber_and_tow_kg": total_extractable_dry_fiber_kg,
            "actual_fiber_recovery_pct": actual_fiber_recovery_pct,
            "yield_variance_vs_clone_std_pct": yield_variance_pct,
            "prime_3l_ug_share_pct": prime_line_fiber_share_pct,
            "average_bale_weight_kg": avg_bale_weight_kg,
            "bale_moisture_compliant": moisture_passed,
            "batch_status": release_status,
        }

3. Cordage Spinning, Woven Polypropylene (WPP) Tape Extrusion & Export Bale Serialization

For integrated packaging and cordage mills, our ERP extends from fiber bale store to spinning frames, extrusion lines, and container stuffing:

• Hackling, Drawing, Batching-Oil Emulsion & Twine/Rope Spinning: Tracks sisal bale opening, batching oil/rot-proofing emulsion application, sliver regularity across 1st/2nd/3rd drawing passages, and spindle twist-per-meter (TPM) and runnage (meters per kg) for agricultural baler twine and marine hawser ropes.
• PP Raffia Tape Extrusion, Circular Looms & Cutting/Stitching/Printing: Monitors virgin PP homopolymer + calcium carbonate masterbatch extrusion denier (700–1200D), 6-shuttle circular loom warp/weft consumption, BOPP/LDPE lamination coating weight (GSM), flexo printing ink usage, and automated BCS cut-and-stitch bag bundle counting.
• 250 kg High-Density Export Bale Barcode & Container Stuffing Manifest: Prints weather-resistant QR/barcode bale tags encoding Estate Code, Grade (3L/UG/SSUG/Tow), Press Number, Gross/Tare/Net Weight, and Moisture %, and compiles the shipping-line container VGM (Verified Gross Mass), KEPHIS phytosanitary dossier, and KRA eTIMS export invoice.