Industry Overview
Paper and paper products continue to hold a prominent position among packaging materials, alongside metal containers and foils, glass, rigid and flexible plastics, cellulosic films, textiles including jute, woven plastics, and wood. Paper-based packaging includes bleached and unbleached kraft paper, corrugated and solid fibre boards, and various converted products such as wax-coated, plastic-coated, and bitumen-coated materials.
Corrugated and solid fibre board boxes have increasingly replaced conventional wooden boxes as transport containers because of their light weight, satisfactory strength, cushioning properties, easy handling, low cost, and adaptability to interior packing. Paper is extensively used for boxes, bags, sealing tapes, drums, tubes, and cushioning applications. The report notes that approximately 35 per cent of total paper production goes to the packaging industry and anticipates continued growth in packaging papers and boards with industrial development.
The project proposes manufacturing corrugated boxes from corrugated cardboard sheets purchased from established corrugators. The industry can operate by converting corrugated sheets or rolls into boxes and cartons for packaging applications. The report also covers corrugated fibre board types, raw materials, market structure, manufacturing processes, testing, research and development, plant and machinery, plant layout, suppliers, and project economics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 Ton/Day |
| Land & Building (23,300 sq.mt.) | Rs. 7.40 Cr |
| Plant & Machinery | Rs. 4.93 Cr |
| Working Capital for 1 Month | Rs. 1.92 Cr |
| Total Capital Investment | Rs. 14.87 Cr |
| Rate of Return | 34% |
| Break Even Point | 51% |
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
- B FLUTE SINGLE FACE BOARD
- A FLUTE DOBLE 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
- FUTURE TRENDS
- THE MAJOR USER INDUSTRIES OF THIS VERSATILE PACKING MATERIAL ARE:-
- MARKET SEGEMENTATION OF CORRUGATED BOXES
- 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
- GLOBAL MARKETING POSITION OF CORRUGATED BOARD AND BOXES
- 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
- 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
- SPECIFICATIONS:-
- 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 & MACHINERY FOR CORRUGATED BOARD & 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
- 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
A corrugated box manufacturing project involves converting corrugated cardboard sheets into boxes and cartons for packaging applications. The report specifically proposes making corrugated boxes from corrugated cardboard sheets purchased from established corrugators. Manufacturing generally involves operations such as cutting, creasing, slotting, printing, pasting, folding, and forming according to the required box design. Corrugated packaging is widely used because it combines relatively low weight with useful strength, cushioning, easy handling, and adaptability to different packaging requirements.
The main types covered in the report are single faced, double faced, double wall, and triple wall corrugated fibre boards. Single faced board has one liner facing and provides cushioning for products used in interior packing. Double faced board has a facing on each side of the corrugating member and is commonly used for shipping containers and protective packing. Double wall board combines three flat facings with two corrugating members, while triple wall board combines four flat facings with three corrugating members for applications requiring greater strength.
Key raw materials identified in the report include kraft paper, corrugating medium, liner boards, cardboard, adhesive, sodium silicate, and starch. Corrugated board is formed by combining liner material with a corrugated medium, while adhesives are used to bond the layers. The specific grades and specifications required depend on the desired board construction and final packaging application. Reliable raw-material sourcing is important because the quality of paper and adhesive directly influences the strength and performance of the finished corrugated packaging.
The report identifies several machines and equipment categories for corrugated board and box conversion. These include a single face corrugating machine, board cutting machine, pasting machine, sheet press, heavy duty eccentric slotter, corrugating sheet printing machine, bar rotary cutting and creasing machine, and partition slotter. The actual machinery configuration depends on whether a unit produces corrugated board, converts purchased sheets into boxes, or performs additional printing and finishing operations. Equipment specifications and technical data are also included in the report.
Corrugated boxes offer several packaging advantages, including light weight, low cost, easy setup and handling, limited storage requirements, cushioning properties, and adaptability to interior packing. They can also provide attractive printing and are suitable for a broad range of packaging applications. Their relatively strong structure allows them to serve as transport containers while remaining easier to handle than many conventional alternatives. The report highlights these characteristics as important factors behind the growth and wider use of corrugated and fibre-based packaging.
The report covers a wide range of carton styles, including regular slotted cartons, overlap slotted cartons, centre special slotted cartons, full overlap slotted cartons, half slotted cartons with covers, telescope cartons, design style cartons, double cover cartons, interlocking double cover cartons, bliss cartons, double thickness score line boxes, double slide cartons, and triple slide cartons. Different carton constructions are selected according to product dimensions, loading requirements, handling conditions, stacking needs, and the desired method of closing or opening the package.
Important considerations include raw-material availability, suitable plant location, machinery selection, plant layout, production process, product specifications, quality testing, labour requirements, utilities, and market access. The report also addresses suppliers of plant and machinery, kraft paper, cardboard, kraft liner board, lamination adhesive, printing inks, and other supplies. Operational planning should align the machinery and production flow with the intended carton range and quality requirements. Project economics, working capital, fixed capital, and other financial considerations should also be evaluated before implementation.
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