CORRUGATED BOXES AND MONO CARTON MAKING PLANT

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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 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.

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.

Double Wall corrugated fibre Boards:

Double wall corrugated fibre boards comprise of three flat facings and tow corrugating members combined. The principal use of double wall corrugating fibre board is in making boxes. Excellent strength of boxes made from such a fibre board permits the use of boxes of greater size and gross weight.

Tripple wall corrugated Fibre Boards:

Tripple wall corrugated fibre board sheet comprises of four flat facings and three corrugated members combined. These fibre boards are used for making boxes which are used for packing large and heavy articles.

Solid fibre board’s containers are made from solid fibre sheets by gluing or lamination two or more plies of paper boards together on a pasting machine to form a single sheet. By varying the number of sheets the thickness of the resulting solid fibre board is altered. Besides their use as containers, owing to their toughness, solid fibre boards are also used as lithographic cutouts, advertising display sings, separator pads and partitions.

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Description

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
USES & APPLICATIONS
INDIAN PACKAGING INDUSTRY
MARKET DATA
PACKAGING MARKET SEGMENTATION
PACKAGING MARKET SEGMENTATION
CORRUGATION INDUSTRY IN INDIA
KEY TRENDS
FUTURE OF CORRUGATION INDUSTRY
MARKET OVERVIEW OF CORRUGATED BOARD & BOXES
FUTURE TRENDS
INDIA CORRUGATED BOX MARKET IS EXPECTED TO REACH OVER INR 63,000 CRORE BY FY’2023
FUTURE TRENDS
MARKET SEGMENTATION OF CORRUGATED BOXES
MARKET SHARE (2020)
TRENDS IN CORRUGATED PACKAGING
FIT-TO-PRODUCT
SUSTAINABILITY
DIGITAL PRINTING GROWTH
GLOBAL MARKETING POSITION OF CORRUGATED BOARD AND BOXES
SINGLE-WALL CORRUGATED BOXES SOLD IN LARGEST NUMBERS
SLOTTED BOXES TO REGISTER HIGHEST DEMAND
PROCESSED FOOD SECTOR GENERATED HIGHEST REVENUE
ASIA-PACIFIC (APAC) REGION TO OBSERVE LARGEST SHARE AND FASTEST GROWTH
INDIAN CORRUGATED BOXES INDUSTRY RISING IN INTERNATIONAL MARKET
RAW MATERIALS
KRAFT PAPER:-
ADHESIVE:-
SODIUM SILICATE:-
STARCH:-
FUTURE PROSPECT OF CORRUGATED BOXES
B.I.S. SPECIFICATION
FOR MONO CARTON BOX BOARD
MANUFACTURING PROCESS OF CORRUGATED BOXES
BOX MAKING:-
1. 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)
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
WJ SERIES AUTOMATIC CORRUGATED CARDBOARD PLANT
FEATURES
SPECIFICATIONS
CONTENT OF THE LINE
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:
CORRUGATING ADHESIVE
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
EXAMPLE 4
EXAMPLE 5
USES AND APPLICATION OF MONO CARTON
FOLDING CARTON
MARKET OVERVIEW OF MONO CARTON
GROWING DEMANDS
FUTURE TRENDS
MARKET TRENDS OF MONO CARTON
GROWING DEMAND FOR FOLDING CARTON PACKAGING IN INDIA AND SOUTHEAST ASIA
CONSOLIDATION TO CONTINUE IN PAPER PRODUCTION AND CONVERSION SEGMENTS
A FEW LARGE PLAYERS, ALONG WITH MANY SMALL COMPANIES
MARKET OF PAPER AND PAPER PRODUCTS
MANUFACTURERS/SUPPLIERS OF MONO CARTON
INNOVATION IN FOLDING CARTON
MANUFACTURING PROCESS OF MONO CARTON
THE FOLDING CARTON MANUFACTURING PROCESS OVERVIEW
1. DIE-LINES AND SHEET LAYOUT
2. SHEETING & PRINTING
3. POST-PRESS FINISHES
4. DIE-CUTTING
5. FOLDING/GLUING
SEQUENCES IN MONO CARTON MANUFACTURE
DUPLEX BOARD BOXES (MONO CARTONS)
TYPES OF MONO CARTON
MONO CARTONS
FOLDING CARTONS
LITHO-LAMINATED CARTONS
E FLUTED
G FLUTED
PLASTIC CARTONS
COSMETICS
FRAGRANCES
HEALTHCARE
RIGID BOXES
MANUFACTURING STEPS IN FOLDING CARTON MAKING
PACKAGE DESIGN
LAYOUT
FIGURE 2 & 3
DIE MAKING
FIGURE 4
FIGURE 5
SHEETING
A WORD ABOUT “GRAIN”
PRINTING
SCREEN PRINTING BASIC
FIGURE 6
PRE-PRESS
THE FOUR PRIMARY PRINTING PROCESSES
FIGURE 7
FIGURE 8
FIGURE 9
CUTTING & CREASING
FIGURES 11
FIGURES 12
CONVERTING PROCESS
FIGURE 13
OTHER FINISHING
FOIL STAMPING
EMBOSSING/DEBOSSING
FIGURE 14
WINDOWING
FIGURE 15
FIGURE 16
FIGURE 17
FIGURE 18
LOCATION
LIST OF LAB EQUIPMENTS FOR PRODUCT ANALYSIS
COMPLETE PLANT AND MACHINERY SUPPLIERS FOR CORRUGATED
BOXES AND MONO CARTON
SUPPLIERS OF LAMINATING MACHINE
ADDRESSES OF RAW MATERIALS SYPPLIERS
SUPPLIERS OF KRAFT PAPER
SUPPLIERS OF CARDBOARD
SUPPLIERS OF KRAFT LINER BOARD
SUPPLIERS OF LAMINATION ADHESIVE
PRINTING INKS & OTHER SUPPLIES
LIST OF LAB EQUIPMENTS FOR PRODUCT ANALYSIS
CARTON & MONO CARTON INDUSTRY CONSULTANT IN INDIA

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)

Additional information

Plant Capacity

220 MT/Day
Land & Building

(20000 sq.mt.)
Plant & Machinery

US$ 4000000
Rate of Return

44%
Break Even Point

36%

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