Detailed Project Report (DPR) on automatic corrugated boxes making plant

AUTOMATIC CORRUGATED BOXES MAKING PLANT

 [CODE NO.4163] 

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 enter 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.

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.

The corrugated board and boxes making industry is  reserved for development material, i.e. Kraft paper is in short supply in the country and imported from various countries to meet the growing demand,

M/s. Hindustan Paper Corporation, New Delhi may be contacted frequent allotment of imported paper.

Corrugating medium and craft paper lining form the layers (Plies) of corrugated cardboard sheets. There are two types of industries in India side-by-side:-

1. Those procuring media & craft papers from their manufacturers to corrugate and make corrugated board to be sold as it is or to make corrugated board boxes for packaging industries.

2. Those units which use corrugated cardboard sheet coils/rolls to convert them in boxes & cartons for packaging.  

Both the types of industries on operating successfully.

This  project proposes  to make corrugated boxes out  of corrugated  card  board  sheets purchased  from  the  established corrugators.

The industry falls under SSI-Sector irrespective of the fact whether the plant & machineries, used belong to indigenous or imported origin.

COST ESTIMATION

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%

• 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 – 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)