Code #3895
Industry Overview
Tetra Pak is a multinational food processing and liquid carton packaging company of Swedish origin, founded in 1951 by Ruben Rausing. The company is one of the largest producers of aseptic carton packaging and primarily operates in the B2B segment, with particular emphasis on corporate social responsibility and green sourcing.
Tetra Pak develops packaging solutions for liquid products such as milk and juice. Its aseptic packaging technology enables perishable liquid foods to be stored and distributed for extended periods while supporting hygiene, durability, convenience, and preservation. The company operates in more than 150 countries and employs over 21,500 people worldwide. In 2008, 70,538 million liters of liquid food products were sold in Tetra Pak packages, equivalent to 141,379 million packages of different sizes and designs.
The report examines Tetra Pak's sustainability challenges in India and considers strategies for strengthening its environmentally responsible operations. It also covers liquid carton packaging structures, packaging material conversion, form/fill/seal technology, aseptic packaging, openings and sealing techniques, product mix, market segmentation, plastic film and sheet manufacturing methods, manufacturing processes, environmental factors, waste handling, and suppliers.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 1,00,00,000 Pieces |
| Land & Building (5000 sq.mt.) | Rs. 4.45 Cr |
| Plant & Machinery | Rs. 65.09 Cr |
| Working Capital for 2 Month | Rs. 143.00 Cr |
| Total Capital Investment | Rs. 213.00 Cr |
| Rate of Return | 52% |
| Break Even Point | 28% |
Content Index
- INTRODUCTION
- SUITABLE FOR DIFFERNENT SHAPES, SUCH AS BRICK SHAPE, GABLE TO SHAPE, TRIANGLE SHAPE, AND ETC.
- GENERAL TRENDS WITHIN LIQUID CARTONS
- TRENDS WITHIN MILK AND OTHER DIARY PACKAGING
- TRENDS IN JUICE PACKAGING
- TRENDS IN FOOD- AND BEVERAGE PACKAGING MACHINERY
- PLANT LOCATION
- GENERAL CHARACTERISTICS OF THE DISTRICT
- LOCATION & GEOGRAPHICAL AREA
- TOPOGRAPHY
- MAP OF GAUTAM BUDH NAGAR DISTRICT
- LIST OF THE MEDIUM ENTERPRISES IN GAUTAM BUDH NAGAR & NEAR BY AREA
- MAJOR EXPORTABLE ITEM BY NOIDA EXPORT PROCESSING ZONE (NEPZ)-
- PRODUCTS-
- TRANSPORT
- METRO
- NOIDA HAS EXCELLENT METRO CONNECTIVITY.
- ROAD
- A ROAD IN NOIDA
- NOIDA-GREATER NOIDA EXPRESSWAY
- RAIL/AIR
- BUS
- HISTORICAL BACKGROUND
- LIQUID CARTON PACKAGING
- BASIC STRUCTURE 26
- PACKAGING MATERIAL STRUCTURE OF A LIQUID CARTON
- PROTECTION AND PRESERVATION
- PAPERBOARD PRINTING
- LAMINATION AND CREASING
- CUTTING
- THE THREE MAIN PACKAGING MATERIAL CONVERTING STAGES
- THE FORM/FILL/SEAL MACHINE
- PAPER FEED
- PUNCHING AND PATCHING
- PULLTAB ATTACHMENT
- LONGITUDAL STRIP APPLICATION
- ASEPTIC BATH
- TUBE-FORMING
- ASEPTIC RING
- FOLDING
- EXTERNAL CAPPING
- PRINCIPLE LAYOUT OF A FORM/FILL/SEAL-MACHINE
- ASEPTIC AND CHILLED SEGMENT
- OPENING ATTACHMENT
- THERMAL SEALING
- ADHESIVES BONDING
- DISTRIBUTION
- PACKAGING LEVELS
- PRIMARY PACKAGING
- SECONDARY PACKAGING
- TERTIARY PACKAGE
- LIQUID CARTON PACKAGING OPENINGS
- OPENING CATEGORIZATION
- RESEALABLE OPENING
- RECLOSABLE OPENING
- NON-RECLOSABLE OPENING
- 1-STEP AND 2-STEP OPENINGS
- STEP OPENINGS
- STEP OPENING
- TETRA PAK OPENINGS
- PERFORATION™
- EASY OPENING™
- STRAW HOLE/ STRAWS
- PULLTAB™
- FIG THE PERFORATION™, EASY OPENING™, STRAW HOLE AND PULLTAB™
- OPENING SOLUTIONS (COURTESY OF TETRA PAK AB )
- GRANDTAP
- BAJKAL
- HURON
- FIG THE GRANDTAP, BAJKAL, AND HURON OPENING SOLUTIONS (COURTESY OF TETRA PAK AB)
- RECAP™
- FLEXICAP™
- SIMPLYPULL™
- FLIPCAP
- FIG THE RECAP™, FLEXICAP™, SIMPLYPULL™ AND FLIPCAP OPENING SOLUTIONS (COURTESY OF TETRA PAK AB )
- TETRA PAK – BENEFITS
- IT HAS FOLLOWING BENEFITS:
- PROTECTION
- PRESERVATION
- COMMUNICATION
- CONVENIENCE
- ASEPTIC PACKAGING
- PROPERTIES OF ASEPTIC PACKAGING MATERIAL
- ADVANTAGES OF ASEPTIC PACKAGING TECHNOLOGY
- FEW ADVANTAGES IN ALL CATEGORIES
- ADVANTAGES OF BULK ASEPTIC PACKAGING
- ADVANTAGES IN PROTECTION
- ADVANTAGES IN LOGISTICS
- LOWER TRANSPORT WEIGHT
- LOWER STORAGE COSTS
- ADVANTAGES IN GENERAL
- TYPICAL PACKAGING APPLICATIONS
- SEALING TECHNIQUE AT TETRA PAK
- FIGURE : MATERIAL LAYERS OF A TETRA BRIK ASEPTIC PACKAGE.
- FIGURE : PRINCIPLE SKETCH OF THE MANUFACTURING OF THE LONGITUDINAL SEALING (LS) AND THE TRANSVERSAL SEALING (TS).
- FIGURE : PRINCIPLE SKETCH OF THE TS PROCESS, SHOWING THE DIFFERENT PARTS.
- PRODUCT MIX OF TETRA PAK
- PRODUCT MIX
- TETRA PAK PRODUCT MIX
- TETRA BRIK
- TETRA REX
- TETRA TOP
- TETRA BRIK ASEPTIC
- TETRA CLASSIC ASEPTIC
- TETRA GEMINA ASEPTIC
- TETRA PRISMA ASEPTIC
- TETRA WEDGE ASEPTIC
- TETRA FINO ASEPTIC
- TETRA EVERO ASEPTIC
- TETRA RECART
- LEVELS OF TETRA PAK PRODUCTS
- CORE LEVEL
- ACTUAL LEVEL
- AUGMENTED LEVEL
- MARKET SURVEY
- TETRA PACK CONTAINER MARKET – MARKET SEGMENTATION:
- BASED ON MATERIALS, TETRA PACK CARTONS, THE MARKET IS SEGMENTED INTO,
- ON THE BASIS OF PACKAGED PORTFOLIO, THE MARKET IS SEGMENTED INTO,
- TETRA PACK CONTAINER MARKET - MARKET SEGMENTATION:
- BASED ON MATERIALS, TETRA PACK CARTONS, THE MARKET IS SEGMENTED INTO,
- ON THE BASIS OF PACKAGED PORTFOLIO, THE MARKET IS SEGMENTED INTO,
- BASED ON END USER INDUSTRY, THE TETRA PACK CARTONS MARKET IS SEGMENTED INTO
- BASED ON THE APPLICATIONS, THE TETRA PACK CARTONS MARKET IS SEGMENTED INTO
- TETRA PACK CARTON MARKET - MARKET DYNAMICS:
- TETRA PACK CARTON MARKET - REGIONAL OUTLOOK:
- FIT FOR THE FUTURE
- TETRA PAK LIQUOR MARKET
- PLASTIC FILM AND SHEET MANUFACTURING METHODS
- EXTRUSION
- PRINCIPLE LAYOUT OF A SHEET EXTRUSION PROCESS
- CALENDERING
- PRINCIPLE LAYOUT OF A SHEET CALENDERING PROCESS
- MULTILAYERED PLASTIC FILM AND SHEET MANUFACTURING METHODS
- CO-EXTRUSION
- PRINCIPLE LAYOUT OF A CO-EXTRUSION PROCESS
- MULTILAYER CALENDERING
- PRINCIPLE LAYOUT OF A CO-CALENDERING PROCESS
- KNIFE SPREAD COATING
- PRINCIPLE LAYOUT OF A KNIFE SPREAD COATING PROCESS
- CURTAIN COATING
- PRINCIPLE LAYOUT OF A CURTAIN COATING PROCESS
- SUGGESTED PLASTIC FILM AND SHEET SHAPING METHODS
- THERMOFORMING
- PRINCIPLE LAYOUT OF A VACUUM FORMING PROCESS
- FOLDING
- FOLDING EXAMPLE WITH PREDEFINED FOLDING PATTERN
- PROCESS OF MANUFACTURING
- THEN, WITH THE HELP OF A LASER AND TEMPERATURE CONDITIONS, SUCH A PATTERN IS OBTAINED.
- THE FINISHED TEMPLATE IS WOUND ON SHAFTS
- THESE BLANKS ARE INSTALLED IN THE PRINTING EQUIPMENT AND
- THE PRINTING PROCESS TAKES PLACE ON A HUGE MACHINE.
- EACH INK IS APPLIED SEPARATELY; IT REMINDED ME OF THE WORK
- OF AN INKJET PRINTER.
- THE CORRECT COLOR IS AUTOMATICALLY CONTROLLED.
- AFTER PRINTING, THE LAMINATION PROCESS BEGINS - THE MOST DIFFICULT
- AND SECRET SITE.
- AFTER LAMINATION - CUTTING. THE FINAL STAGE OF WORK - SHRINK PACKAGING.
- PROCESS FLOW DIAGRAM
- STERILE SYSTEM TBA/8,, TBA/19
- GENERAL ENVIRONMENT
- CULTURAL AND SOCIAL ENVIRONMENT
- ECONOMIC AND TECHNOLOGICAL ENVIRONMENTS
- POLITICAL AND LEGAL ENVIRONMENT
- FEDERAL, STATE, AND LOCAL REGULATION. LIMIT CHOICES AVAILABLE TO ORGANIZATION.
- COMPETITIVE ENVIRONMENT
- POLITICAL CONDITIONS
- DEMOGRAPHIC ENVIRONMENT
- GLOBAL ENVIRONMENT
- ECOLOGICAL ENVIRONMENT
- THE “GREENING” OF MANAGEMENT
- HANDLING OF WASTE
- MACHINERY SUPPLIERS
- RAW MATERIAL SUPPLIERS
- ALUMINUM FOIL
- PAPER BOARD
- MACHINERY PHOTOGRAPHS
- RAW MATERIAL PHOTOGRAPHS
- PRODUCT PHOTOGRAPHS
Appendix
- 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
Frequently Asked Questions
Aseptic carton packaging is a packaging technology designed to protect and preserve perishable liquid foods for extended storage and distribution. The report describes its application to products such as milk and juice and covers the properties and advantages of aseptic packaging materials. It also examines form/fill/seal equipment, aseptic baths, tube forming, sealing, folding, and other stages involved in producing liquid cartons.
The report identifies a multilayer structure consisting of polymer, paper, polymer, aluminum, polymer, and polymer layers. These layers contribute to the packaging structure and its protection and preservation functions. The report also discusses paperboard printing, lamination and creasing, cutting, longitudinal and transversal sealing, and other material-converting operations used in liquid carton packaging.
The main production stages covered in the report include printing, lamination and creasing, cutting, and subsequent forming, filling, and sealing operations. The form/fill/seal process includes paper feeding, punching and patching, pulltab attachment, longitudinal strip application, aseptic treatment, tube forming, folding, external capping, opening attachment, thermal sealing, and adhesive bonding. The report also describes the overall process flow and packaging distribution levels.
Aseptic packaging supports protection, preservation, communication, and convenience while enabling efficient handling of liquid food products. The report specifically discusses advantages in protection and logistics, including lower transport weight and lower storage costs. It also covers typical packaging applications and the role of aseptic packaging materials in maintaining the required packaging performance.
Liquid carton openings can be categorized as resealable, reclosable, or non-reclosable, with the report also discussing 1-step and 2-step openings. Specific opening solutions covered include PERFORATION™, EASY OPENING™, STRAW HOLE/ STRAWS, PULLTAB™, GRANDTAP, BAJKAL, HURON, RECAP™, FLEXICAP™, SIMPLYPULL™, and FLIPCAP. These solutions address different requirements for opening and, where applicable, reclosing packaged liquid products.
The report covers several plastic film and sheet manufacturing and shaping methods, including extrusion, calendering, co-extrusion, multilayer calendering, knife spread coating, curtain coating, thermoforming, and folding. It also includes references to principle layouts for several processes. These methods are presented in the context of manufacturing packaging-related materials and components.
Plant location considerations in the report include the general characteristics of the district, geographical area, topography, transportation infrastructure, and nearby industrial activity. The report specifically discusses Gautam Budh Nagar and Noida, including metro connectivity, roads, the Noida-Greater Noida Expressway, rail/air connectivity, bus transport, and the Noida Export Processing Zone. These factors can influence access to infrastructure, suppliers, markets, and logistics.
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