Detailed Project Report on corrugated board and boxes automatic plant

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)