Industry Overview
Corrugated packaging has become an important segment of the packaging industry, with paper and paper-based products continuing to occupy a prominent position alongside metal, glass, plastics, cellulosic films, textiles, woven plastics, and wood. Paper is extensively used for boxes, bags, sealing tapes, drums, tubes, and cushioning materials. Corrugated and solid fibre board boxes have increasingly replaced conventional wooden containers because of their light weight, satisfactory strength, low cost, ease of handling, cushioning properties, compact storage requirements, adaptability to interior packing, and suitability for attractive printing.
A corrugating box is produced from corrugated fibre board, which consists of a corrugated member glued to one or both faces of liner board. Common forms include single faced and double faced corrugated fibre boards. Single faced board provides cushioning and is widely used for interior wrapping and protection of fragile products, while double faced board is primarily used for shipping containers and interior protection of glassware and other fragile articles. The project report covers corrugated board and box types, construction and properties, raw materials, manufacturing processes, machinery, testing, sustainability, printing, wastewater treatment, product applications, suppliers, and related technical considerations.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
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
- 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
- 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)
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