Industry Overview
Paper and paper-based products continue to hold a prominent position among packaging materials, alongside metal containers and foils, glass, plastics, cellulosic films, textiles, woven plastics, jute and wood. Packaging papers include bleached and unbleached kraft, corrugated and solid fibre boards, as well as converted products such as wax-coated, plastic-coated and bitumen-coated papers.
Corrugated and solid fibre board boxes have increasingly replaced conventional wooden transport containers because of their light weight, satisfactory strength, cushioning properties, easy handling, low cost and adaptability to different packing requirements. Corrugated boxes also provide advantages such as small storage requirements, attractive printing and broad availability.
Paper is extensively used for boxes, bags, sealing tapes, drums, tubes and cushioning applications. The report notes that approximately 35 per cent of total paper production goes to the packaging industry and anticipates continued growth in packaging papers and boards with industrial development. The project proposes manufacturing corrugated boxes from corrugated cardboard sheets purchased from established corrugators, representing a converting operation within the SSI sector.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 30 Ton/Day |
| Land & Building (12,000 sq.mt.) | Rs. 5.19 Cr |
| Plant & Machinery | Rs. 6.39 Cr |
| Working Capital for 1 Month | Rs. 3.68 Cr |
| Total Capital Investment | Rs. 15.80 Cr |
| Rate of Return | 42% |
| Break Even Point | 44% |
Content Index
- 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
- B FLUTE SINGLE FACE BOARD
- A FLUTE DOUBLE FACE BOARD
- A & A FLUTE DOUBLE WALL BOARD
- A & B DOUBLE WALL BOARD
- PRODUCT USES & APPLICATIONS
- INDIAN PACKAGING INDUSTRY
- MARKET DATA
- PACKAGING MARKET SEGMENTATION
- PACKAGING MARKET SEGMENTATION
- CORRUGATION INDUSTRY IN INDIA
- ORGANISED & UN-ORGANISED INDUSTRY STRUCTURE
- 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
- THE MAJOR USER INDUSTRIES OF THIS VERSATILE PACKING MATERIAL ARE
- MARKET SEGEMENTATION OF CORRUGATED BOXES
- MARKET SHARE (2020)
- WORLD CORRUGATED BOXES MARKET
- CHINA, INDIA TO BE FASTEST GROWING NATIONAL MARKETS
- RECYCLED BOARD TO LEAD CONTAINERBOARD DEMAND
- DEMAND & SUPPLY, COMPETITION - CORRUGATED BOXES
- CORRUGATION: FUTURE TRENDS
- TRENDS IN CORRUGATED PACKAGING
- E-COMMERCE
- 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
- SOME OF THE KEY MARKET PLAYERS IN THE CORRUGATED BOXES MARKET INCLUDE:
- INDIAN CORRUGATED BOXES INDUSTRY RISING IN INTERNATIONAL MARKET
- 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:-
- FUTURE PROSPECT OF CORRUGATED BOXES
- FUTURE PROSPECTIVE OF THE INDUSTRY
- EXPLOSION OF E-COMMERCE –
- DIGITAL PRINTING GROWTH –
- SUSTAINABILITY –
- TARGET CUSTOMERS
- ABOUT THE PRODUCT
- B.I.S. SPECIFICATION
- TYPES OF CORRUGATIONS
- MANUFACTURING OF CORRUGATED PACKAGING
- 1) THE CONTAINERBOARD COMBINING PROCESS
- 2) THE BOX MANUFACTURING PROCESS
- A) PRINTING PROCESS –
- B) PUNCHING PROCESS –
- C) FORMING PROCESS –
- D) BUNDLING PROCESS –
- 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)
- 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
- EXAMPLE 1
- EXAMPLE 2
- EXAMPLE 3
- EXAMPLE 4
- EXAMPLE 5
- LOCATION
- SUPPLIERS OF PLANT AND MACHINERY FOR CORRUGATED BOARD AND BOXES
- SUPPLIERS OF LAMINATING MACHINE
- SUPPLIERS OF KRAFT PAPER
- SUPPLIERS OF CARDBOARD
- SUPPLIERS OF KRAFT LINER BOARD
- SUPPLIERS OF LAMINATION ADHESIVE
- PRINTING INKS & OTHER SUPPLIES
- LIST OF THE MACHINES (CHINA MAKE)
Appendix
- 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)
Frequently Asked Questions
A corrugated box manufacturing project involves converting corrugated cardboard sheets into finished cartons and packaging boxes. The project described in the report proposes purchasing corrugated cardboard sheets from established corrugators and converting them into boxes. Typical operations can include printing, punching, creasing, slotting, forming, pasting and bundling. The finished products can serve diverse packaging requirements because corrugated boxes combine relatively low weight, cushioning properties, ease of handling, storage efficiency and adaptability to different product dimensions and packaging designs.
The main types described in the report are single faced, double faced, double wall and tripple wall corrugated fibre boards. Single faced board has one liner attached to a corrugated member and is commonly used for cushioning and interior packing. Double faced board has liners on both sides and is widely used for shipping containers. Double wall construction combines additional liners and corrugated members for greater strength, while tripple wall construction provides still higher structural strength for large or heavy articles.
The principal materials identified in the report include kraft paper, corrugating medium, liner boards, cardboard and adhesives. Sodium silicate and starch are also listed in connection with corrugating adhesive requirements. The specific material combination depends on the board construction, box specification, required strength, printing requirements and end-use application. For a converting unit purchasing ready corrugated sheets, the primary incoming material is the corrugated cardboard sheet, while printing and bonding operations may require additional consumables and supplies.
Corrugated boxes are commonly used as transport, shipping and protective packaging for a wide range of products. Their cushioning properties make them suitable for fragile goods, while their strength-to-weight characteristics support the packaging of heavier products. The report identifies applications across packaging-intensive sectors and discusses uses for products requiring interior protection, partitions and containers. Printing capability also allows corrugated cartons to carry product information, branding and handling instructions.
The report lists equipment such as a single face corrugating machine, board cutting machine, pasting machine, sheet press, heavy duty eccentric slotter, corrugating sheet printing machine, bar rotary cutting and creasing machine and partition slotter. The exact equipment configuration depends on whether a unit manufactures corrugated board itself or only converts purchased corrugated sheets into boxes. Printing, cutting, creasing, slotting, forming and bundling equipment can be selected according to the required box designs and production workflow.
Corrugated boxes are preferred in many applications because they offer a combination of low weight, lower cost, easy handling, cushioning and efficient storage. The report also highlights their adaptability to interior packing and attractive printing. Corrugated packaging can be produced in different board constructions and box styles to accommodate varying product sizes and protection requirements. These characteristics have enabled corrugated and solid fibre containers to replace conventional wooden containers in several transport and packaging applications.
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