Industry Overview
India’s paper-making industry is increasingly responding to the requirements of the container and packaging industry by improving the quality and range of paper products. Textile, tea, tobacco, and coffee are among the major consumers of paper in the country, while approximately 35 per cent of total paper production is used by the packaging industry. As industrial activity advances, production of paper and paperboard is expected to increase, with significant growth anticipated in packaging papers and boards.
Paper is increasingly replacing traditional packaging materials because it is economical, lightweight, easy to handle, and adaptable to different packaging requirements. Corrugated boxes and solid fibre containers are widely used as alternatives to wooden boxes. Corrugated fibre boards offer advantages including light weight, low cost, easy handling and storage, cushioning properties, adaptability to interior packing, attractive printing, and broad availability.
The principal types include single-faced, double-faced, double-wall, and triple-wall corrugated fibre boards. Single-faced boards are commonly used for interior wrapping and cushioning, while double-faced boards are widely used for shipping containers and protection of fragile products. Double-wall and triple-wall boards provide progressively greater strength and are used for larger and heavier packages. Solid fibre boards, produced by laminating two or more paperboard plies, are also used for containers, display signs, separator pads, partitions, and other applications requiring toughness.
Cost Estimation
| Cost Parameter | Value |
|---|---|
| Plant Capacity | 220 MT/Day |
| Land & Building (20000 sq.mt.) | Rs. 10.59 Cr |
| Plant & Machinery | Rs. 28.00 Cr |
| Working Capital for 1 Month | Rs. 13.19 Cr |
| Total Capital Investment | Rs. 54.08 Cr |
| Rate of Return | 44% |
| Break Even Point | 36% |
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
- USES & APPLICATIONS
- INDIAN PACKAGING INDUSTRY
- MARKET DATA
- PACKAGING MARKET SEGMENTATION
- PACKAGING MARKET SEGMENTATION
- CORRUGATION INDUSTRY IN INDIA
- 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
- MARKET SEGMENTATION OF CORRUGATED BOXES
- MARKET SHARE (2020)
- TRENDS IN CORRUGATED PACKAGING
- 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
- INDIAN CORRUGATED BOXES INDUSTRY RISING IN INTERNATIONAL MARKET
- RAW MATERIALS
- KRAFT PAPER:-
- ADHESIVE:-
- SODIUM SILICATE:-
- STARCH:-
- FUTURE PROSPECT OF CORRUGATED BOXES
- B.I.S. SPECIFICATION
- FOR MONO CARTON BOX BOARD
- MANUFACTURING PROCESS OF CORRUGATED BOXES
- BOX MAKING:-
- 1. 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
- WJ SERIES AUTOMATIC CORRUGATED CARDBOARD PLANT
- FEATURES
- SPECIFICATIONS
- CONTENT OF THE LINE
- 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:
- CORRUGATING ADHESIVE
- EXAMPLE 1
- EXAMPLE 2
- EXAMPLE 3
- EXAMPLE 4
- EXAMPLE 5
- USES AND APPLICATION OF MONO CARTON
- FOLDING CARTON
- MARKET OVERVIEW OF MONO CARTON
- GROWING DEMANDS
- FUTURE TRENDS
- MARKET TRENDS OF MONO CARTON
- GROWING DEMAND FOR FOLDING CARTON PACKAGING IN INDIA AND SOUTHEAST ASIA
- CONSOLIDATION TO CONTINUE IN PAPER PRODUCTION AND CONVERSION SEGMENTS
- A FEW LARGE PLAYERS, ALONG WITH MANY SMALL COMPANIES
- MARKET OF PAPER AND PAPER PRODUCTS
- MANUFACTURERS/SUPPLIERS OF MONO CARTON
- INNOVATION IN FOLDING CARTON
- MANUFACTURING PROCESS OF MONO CARTON
- THE FOLDING CARTON MANUFACTURING PROCESS OVERVIEW
- 1. DIE-LINES AND SHEET LAYOUT
- 2. SHEETING & PRINTING
- 3. POST-PRESS FINISHES
- 4. DIE-CUTTING
- 5. FOLDING/GLUING
- SEQUENCES IN MONO CARTON MANUFACTURE
- DUPLEX BOARD BOXES (MONO CARTONS)
- TYPES OF MONO CARTON
- MONO CARTONS
- FOLDING CARTONS
- LITHO-LAMINATED CARTONS
- E FLUTED
- G FLUTED
- PLASTIC CARTONS
- COSMETICS
- FRAGRANCES
- HEALTHCARE
- RIGID BOXES
- MANUFACTURING STEPS IN FOLDING CARTON MAKING
- PACKAGE DESIGN
- LAYOUT
- FIGURE 2 & 3
- DIE MAKING
- FIGURE 4
- FIGURE 5
- SHEETING
- A WORD ABOUT “GRAIN”
- PRINTING
- SCREEN PRINTING BASIC
- FIGURE 6
- PRE-PRESS
- THE FOUR PRIMARY PRINTING PROCESSES
- FIGURE 7
- FIGURE 8
- FIGURE 9
- CUTTING & CREASING
- FIGURES 11
- FIGURES 12
- CONVERTING PROCESS
- FIGURE 13
- OTHER FINISHING
- FOIL STAMPING
- EMBOSSING/DEBOSSING
- FIGURE 14
- WINDOWING
- FIGURE 15
- FIGURE 16
- FIGURE 17
- FIGURE 18
- LOCATION
- LIST OF LAB EQUIPMENTS FOR PRODUCT ANALYSIS
- COMPLETE PLANT AND MACHINERY SUPPLIERS FOR CORRUGATED BOXES AND MONO CARTON
- SUPPLIERS OF LAMINATING MACHINE
- ADDRESSES OF RAW MATERIALS SYPPLIERS
- SUPPLIERS OF KRAFT PAPER
- SUPPLIERS OF CARDBOARD
- SUPPLIERS OF KRAFT LINER BOARD
- SUPPLIERS OF LAMINATION ADHESIVE
- PRINTING INKS & OTHER SUPPLIES
- LIST OF LAB EQUIPMENTS FOR PRODUCT ANALYSIS
- CARTON & MONO CARTON INDUSTRY CONSULTANT IN INDIA
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
Corrugated fibre boards are primarily used for protective packaging, shipping containers, boxes, wrapping, and interior packing. Their layered construction provides cushioning and structural strength while keeping packaging relatively lightweight. Single-faced boards are commonly used for wrapping and cushioning fragile products, whereas double-faced boards are widely used for shipping containers. Double-wall and triple-wall boards are suitable for applications requiring greater strength, including larger and heavier packages.
The main types described in the report are single-faced, double-faced, double-wall, and triple-wall corrugated fibre boards. Single-faced board has one liner attached to a corrugated medium and is commonly used for wrapping and cushioning. Double-faced board has liners on both sides and is widely used for shipping containers. Double-wall board combines three flat facings with two corrugated members, while triple-wall board combines four flat facings with three corrugated members for applications demanding higher strength.
Corrugated boxes offer a combination of low weight, cost efficiency, protection, and handling convenience. The report identifies light weight, low cost, easy setup, limited storage requirements, cushioning properties, easy handling, adaptability to interior packing, attractive printing, and wide availability as key advantages. These characteristics make corrugated packaging suitable for a broad range of industrial and consumer products and enable it to replace heavier traditional packaging options in many applications.
The report identifies kraft paper, adhesive, sodium silicate, and starch as raw materials associated with corrugated box production. Kraft paper provides the principal paper-based structure for liners and related components, while adhesives bond the layers during conversion. Sodium silicate and starch are identified in the report as materials used in the adhesive system. The precise material formulation depends on the board construction, equipment, product requirements, and manufacturing process.
The manufacturing process generally converts paper into corrugated board and then converts the board into the required box design. The report covers corrugation, board cutting, pasting, pressing, slotting, printing, cutting and creasing, partition production, and box making. Different carton styles can then be produced according to the required dimensions and configuration. Equipment selection varies according to production requirements, board specifications, printing needs, box styles, and the degree of automation required.
A mono carton is a paperboard packaging format commonly produced as a folding carton for products such as cosmetics, fragrances, and healthcare items. The report describes a manufacturing sequence involving die-lines and sheet layout, sheeting and printing, post-press finishing, die-cutting, and folding or gluing. Additional processes can include cutting and creasing, foil stamping, embossing or debossing, and windowing. These operations allow cartons to be produced with specific shapes, finishes, structural features, and presentation requirements.
Successful planning requires consideration of production capacity, land and building requirements, plant and machinery, working capital, raw materials, utilities, labour, product specifications, and market requirements. The report also covers plant economics, manufacturing equipment, laboratory equipment, suppliers, process flow, and product analysis. Equipment should be selected according to the required board types, box styles, printing and converting operations, and desired production scale. Adequate quality control and reliable raw-material sourcing are also important for consistent board and box performance.
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