CORRUGATED BOARD AND BOXES AUTOMATIC PLANT
[CODE NO.3781]
The materials now available for packaging are paper and paper products, metal containers and foils, glass, plastics-rigid and flexible, cellulosic films, textiles including jute, woven plastics and wood. Among the packaging materials, paper and paper based products continue to occupy a predominent place. Paper based materials used for packaging include bleached and unbleached kraft, corrugated and solid fiber boards and a large variety of converted items like wax coated, plastic coated, bitumen coated etc. Corrugated and solid fibre board boxes have replaced the conventional wooden boxes as transport containers because of their light weight and satisfactory strength. There are, however, several areas in which this sector is laggin behind the developed countries; they include mainly production of parchment paper for use in packaging of biscuits etc. Sack Kraft paper and high strength Kraft for producing corrugated fibre board of good strength characteristics.
Packaging has been assuming importance in the context of growth of industries in general and consumer industries in particular. Paper is one of the most important materials that enters packaging. Paper is extensively used for making boxes, bags, sealing tapes, drums and tubes and as cushioning materials.
Paper makers in the country are becoming conscious of the needs of container industry and are working to improve the existing qualities. In India textile, tea, tobacco and coffee are probably the largest consumers of papers. Out of the total paper production about 35 per cent goes to the packaging industry. With the advancement of industry, the production of paper and paper board is bound to increase, and the major increase will be in the field of packaging papers and boards. Paper is intact replacing the older materials used for packaging. In addition, paper in packaging is economical; light easy to handle and superior. Corrugated boxes and solid fibre containers are extensively being used in place of wooden boxes.
The lower cost, light weight and superiority over other packaging have been the key to the remarkable growth of fiber boxes. The advantages of corrugated boxes to other packaging materials may be summed as under.
1. Light weight.
2 Low cost.
3. Easy setting up and letting.
4. Small storage space required.
5. Cushioning properties.
6. Easy handling.
7. Adaptability to interior packing.
8. Attractive printing.
9. Wide source of supply.
A corrugating box is made from corrugating fibre board which is a structure formed by glueing a liner board to one or both faces of a corrugated member.
The common types of corrugated fibre boards are:
Single Faced Corrugated Fibre Boards:
Single faced corrugated fibre board is made by gluing a flat sheet of liner board to a sheet of corrugating machine and formed into a series of arches. Single faced board provides a considerable amount of cushioning for any product wrapped in it. These boards are extensively used for wrapping of interior packing. Fragile items are often enclosed in this type of fibre board before packed in larger containers.
Double Faced Corrugated Fibre Boards:-
In this type of corrugated fibre boards, one flat facing is glued to each side of corrugating member, the primary use is for shipping containers. It can also be used in the form of interior packing of glass wares and other fragile articles which require protection.
COST ESTIMATION
Plant Capacity 32 MT/Day
Land & Building (12,000 sq.mt.) US$ 10.40 Cr
Plant & Machinery US$ 11.84 Cr
Working Capital for 2 Month US$ 9.47 Cr
Total Capital Investment US$ 34.24 Cr
Rate of Return 46%
Break Even Point 40%
INTRODUCTION
THE COMMON TYPES OF CORRUGATED FIBRE BOARDS ARE:
SINGLE FACED CORRUGATED FIBRE BOARDS:
DOUBLE FACED CORRUGATED FIBRE BOARDS:-
DOUBLE WALL CORRUGATED FIBRE BOARDS:
TRIPPLE WALL CORRUGATED FIBRE BOARDS:
CONSTRUCTION & PROPERTIES
TYPES OF BOARDS
PRODUCT USES & APPLICATIONS
MARKET OVERVIEW OF CORRAGATED PACKAGING
SUSTAINABILITY
RETAIL CHANGES
DIGITAL PRINTING ADVANCEMENTS
GLOBAL MARKETING POSITION OF CORRUGATED BOARD AND BOXES
BREAKUP BY MATERIAL USED:
BREAKUP BY END USE:
THE MAJOR USER INDUSTRIES OF THIS VERSATILE PACKING MATERIAL ARE
RAW MATERIALS
KRAFT PAPER:-
CORRUGATING MEDIUM:-
LINER BOARDS:-
CARD BOARD:-
ADHESIVE:-
SODIUM SILICATE:-
STARCH:-
TESTING
RESEARCH AND DEVELOPMENT
1. HONEY COMB BOARDS:
2. CROSS-FLUTED BOARD:-
3. HESSIAN LAMINATED BOARD:-
4. MOLDED CORRUGATED PULP:-
B.I.S. SPECIFICATION
TYPES OF CORRUGATIONS
SEQUENCES TO MANUFACTURE CORRUGATED
OUTLINE OF MANUFACTURING PROCESS AND MATERIAL UTILIZED
FIGURE: OVERVIEW OF MANUFACTURING PROCESS FLOW
FOR CORRUGATED PACKAGING
(1) CONTAINERBOARD
TABLE: EXTRACTED FROM THE CLASSIFICATION TABLE
FOR PAPERBOARD TYPES
FIGURE: TYPICAL ADHESIVES FOR COMBINING INGREDIENTS
AND GLUE MANUFACTURE PROCESS FLOW
PRINTING INKS
TABLE: CHARACTERISTICS OF PRINTING INKS USED
FOR CORRUGATED PACKAGING
JOINT ADHESIVES
FIGURE: FORMING OF A CORRUGATED BOX
FIGURE: METHOD OF FORMING OF A CORRUGATED BOX
3) MANUFACTURING PROCESSES
(2) BOX MANUFACTURING PROCESS
PRINTING PROCESS – PRINTER SLOTTER -
②PRINTING AND FORMING PROCESSES – FLEXO FOLDER GLUER -
③ PUNCHING PROCESS- DIE CUTTER –
4) WASTEWATER TREATMENT PROCESS
(1) DISCHARGE ROUTES FOR WASTEWATER AND WASTES
FIGURE DISCHARGE ROUTES FOR WASTEWATER AND WASTES
(2) WASTEWATER TREATMENT METHODS
TABLE: TYPES OF WASTEWATER TREATMENT METHODS
PROCESS OF MANUFACTURE
BOX MAKING:-
REGULAR SLOTTED CARTON
2. OVERLAP SLOTTED CARTON:-
3. CENTRE SPECIAL SLOTTED CARTON.
4. CENTRE SPECIAL OVERLAP SLOTTED CARTON
5. FULL OVERLAP SLOTTED CARTON (FOL)
6. CENTRE SPECIAL FULL OVERLAP SLOTTED CARTON (CSFOL)
7. HALF SLOTTED CARTON WITH COVER (SPTHS)
8. HALF SLOTTED CARTON WITH HALF SLOTTED PARTIAL COVER (PTHS)
9. FULL TELESCOPE HALF SLOTTED CARTON (FTHS)
10. DESIGN STYLE CARTON WITH COVER (SCD)
11. FULL TELESCOPE DESIGN STYLE CARTON (FTD)
12. PARTIAL TELESCOPE DESIGN STYLE CARTON (FTD)
13. DOUBLE COVER CARTON (DC)
THREE PIECE BOX:
TUBE WITH TWO COVERS OF SPECIFIED DEPTH.
14. INTERLOCKING DOUBLE COVER CARTON:-
15. BLISS CARTONS (NO. 2 & NO. 4 STYLE)
16. DOUBLE THICKNESS SCORE LINE BOXES
17. DOUBLE SLIDE CARTONS (DS)
18. TRIBLE SLIDE CARTON (TS)
PROCESS FLOW DIAGRAM
MACHINES REQUIRED & THEIR DESCRIPTION
SINGLE FACE CORRUGATING MACHINE:-
BOARD CUTTING MACHINE:-
PASTING MACHINE
SHEET PRESS:
HEAVY DUTY ECCENTRIC SLOTTER:
CORRUGATING SHEET PRINTING MACHINE:-
4. BAR ROTARY CUTTING & CREASING MACHINE
PARTITION SLOTTER:
FLOW CHART OF MANUFACTURING PROCESS
CORRUGATING ADHESIVE
LOCATION
SUPPLIERS OF PLANT AND MACHINERY FOR CORRUGATED BOARD
AND BOXES
LAMINATING MACHINE
SUPPLIERS OF RAW MATERIALS
KRAFT PAPER
CARDBOARD
KRAFT LINER BOARD
LAMINATION ADHESIVE
PRINTING INKS & OTHER SUPPLIES
LIST OF THE MACHINES (CHINA MAKE)
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
