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Scheme on Corrugated Board and Boxes

Scheme on Corrugated Board and Boxes

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Published by Gourav Agarwal

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Published by: Gourav Agarwal on Jul 05, 2012
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12/02/2013

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SCHEME ON CORRUGATED BOARD AND BOXES
 
INTRODUCTION:
 This project profile in detail foresees setting up of unit to produce corrugated board and boxes.Paper and paper products are versatile industrial raw materials with a wide variety of application inthis era and due to shortage of softwood, wooden packing cases are more and more replaced withcorrugated board- boxes and cartons. As more and more materials are coming in paper packing,availability of raw materials are also on the increase. Thus recycling of waste paper is in demand, whichcan be used to produce products like paperboards, binding sheets, sweet box cartons and other packingcartons.80% of industrial packaging is done by carton boxes due to effective cushioning, light weight, easyto fabricate, easy for storing, easy for disposal, no strapping necessary, printing and advertisingadvantages, must in export market, recyclable etc.
MARKET:
 Corrugated board boxes are used in different area of packing in goods such as: Breweries, Glasswares, Cigarettes, Pharmaceuticals, Biscuits, Milk & Milk products, Soaps, Cosmetics, Tea & Coffee,Hosiery, shoe & footwear industry, toys etc.,
BASIS AND PRESUMPTIONS:
 1. Single shift of 8 hours a day, 25 days a month and 300 days in a year is presumed. Efficientmachines and workers are also presumed.2. Minimum 2 year period is considered for achieving full capacity utilization3. Labour rates are as per the prevailing rates.4. An average interest rate of 14% is considered.5. The estimates are drawn for a production capacity generally considered techno-economicallyviable for model type of manufacturing activity.6. The information supplied is based on a standard type of manufacturing activity viable for modeltype of manufacturing activity.7. The information supplied is based on a standard type of manufacturing activity utilizingconventional techniques of production at optimum level of performance.8. Costs in machinery and equipment, raw materials and the selling prices of the finishedproducts etc., are generally prevailing at the time of preparation of the project profiles and may varydepending upon various factors.9. Whereas some names of manufacturers, suppliers of machinery and equipment, raw materialsetc. are indicated at the end of the profile, those are by no means exclusive or exhaustive.
IMPLEMENTATION SCHEDULE:
 Normally eighteen months are required for the complete implementation of the project, includingmachinery erection, raw materials procurement etc.
PRODUCTION DETAIL AND PROCESS TECHNIQUES:
 
Corrugated Board:
 Corrugated board is made with a corrugated sheet of paper attached to the facing of flat paper,usually kraft by adhesives. In our country, it is mostly produced over a single facer machine here twopaper reels are run together, one layer of paper becomes corrugated after passing through the heatedrolls and the other is brought into contact with it after the former having glued at the tips. Thus both get
 
pasted together and are wound in rolls. The resulting roll is now known as single face/ corrugatedroll/board. By cutting this roll with board cutter and then gluing the corrugated side by a pasting machineand placing 3rd ply of paper over it double faced or 3-ply corrugated board is produced, this board is keptunder pressure in a sheet pressing machines for some time for setting of the wet glued sheets. Similarlyboard can be pasted to form thicker boards i.e.; 5-ply, 7-ply and 9-ply etc.
Corrugated Board Boxes:
 The process of manufacturing boxes or containers constitutes five operations.i) Slitting and Longitudinal Cuttingii) Creasingiii) Slottingiv) Flap or Corner Cuttingv) StitchingAfter passing the sheet through these operations, a box or container is ready, slitting and creasingoperations can simultaneously by carried over a 4 bar rotary cutting and creasing machine. The trimmedand creased sheet is slotted and flap cut on an Eccentric Slotted Machine. Finally, it is either stitched overa stitching machine or glued/taped manually.For partition boxes the half slotted boards are used which can conveniently be produced over a partitionspotter machines.
III. LAND AND BUILDING
 
1 Land 2 lakhs2Building - - Office - 200 sq. ft.Go-down - 2000 sq. ft.Production Area - 2800 sq. ft.Total - 5000 sq. ft.8 lakhs
Total
 
10 lakhs
 
IV. PLANT AND MACHINERY
 
1 Single face paper corrugation Machine 4 lakhs2 Two Board Cutters with one reel stand light model 1 lakhs3 One Sheet Pasting Machine 0.75 lakhs4 One sheet pressing 1 lakhs5 One 4-Bar Rotary Cutting & Creasing 2 lakhs6 One Eccentric Slotted 2 lakhs7Two stitching machines
i) One 36” arm angular head
 
ii) One 48” arm, straight head
 0.55 lakhs.50 lakhs
Total
 
11.8 lakhs
 
 
 Packing, forwarding, excise, insurance, sales-tax,freight etc.1.23 lakhs
Total
 
13.03 lakhs
 Office furniture 0.5 lakhsErection and electrification 1.2 lakhs
Total
 
14.73 lakhs
 
A. RAW MATERIALS (Monthly)
 
1 Kraft paper Rs.40 /- per kg. 50 Tons 20.00 Lakhs2 Glue (Starch) 4 Tons 1.20 Lakhs3 Stitching wire 330 Kg. 0.17 Lakhs
Total
 
21.37 Lakhs
 
B. STAFF AND LABOUR (Monthly)
 
1 Manager 1 5,0002 Accountant cum Typist 1 3,0003 Skilled Worker 6 15,0004 Semiskilled worker 5 10,0005 Unskilled worker 4 6,0006 Watchman cum Peon 2 3,000
Total
 
42,000
 Add perks 20% 8,000
Total
 
50,000
 Electricity 8,000Water 2,000Fire Wood 1,300
Total
 
9,500
 
C. OTHER EXPENDITURE
 
1 Postage and Stationery 2,0002 Telephone 3,0003 Traveling 5,0004 Transport 7,5005 Insurance and Taxes 2,000

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