Detailed Project Report (DPR) on corrugated board and boxes automatic plant (china machine based)

CORRUGATED BOARD AND BOXES AUTOMATIC PLANT (CHINA MACHINE BASED)
[CODE NO.3335]


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                                                :       25.00 Ton./day
land & Building (5000 Sq.Mtrs)                    :       Rs.  5.43  Cr
Plant & Machinery                                           :       Rs.  2.73  Cr
Working Capital for 1 Month                         :       Rs.  4.52  Cr
Total Capital Investment                               :       Rs.  12.95 Cr
Rate of Return                                                :       24%
Break Even Point                                           :        52%

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 DOBLE FACE BOARD    
A & A FLUTE DOUBLE WALL BOARD    
A & B DOUBLE WALL BOARD    
PRODUCT USES & APPLICATIONS    
MARKET SURVEY    
THE MAJOR USER INDUSTRIES OF THIS VERSATILE PACKING MATERIAL ARE:    
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    
THE INDIAN PACKAGING INDUSTRY’S GROWTH CAN BE SPURRED
THROUGH TECHNOLOGY    
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:-    
PRESENT PRODUCTION AND GROWTH PROSPECTS    
B.I.S. SPECIFICATION    
TYPES OF CORRUGATIONS    
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    
TECHNICAL DATA:-    
PARTITION SLOTTER:    
FLOW CHART OF MANUFACTURING PROCESS    
CORRUGATING ADHESIVE    
EXAMPLE 1    
EXAMPLE 2    
EXAMPLE 3    
EXAMPLE 4    
EXAMPLE 5    
LOCATION    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERY    
FOR CORRUGATED BOARD AND BOXES    
M.S. ENTERPRISES    
LAMINATING MACHINE    
KRAFT PAPER    
CARDBOARD    
KRAFT LINER BOARD    
LAMINATION ADHESIVE    
PRINTING INKS & OTHER SUPPLIES    
LIST OF THE MACHINES (CHINA MAKE)    

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET