Report on Corrugated Box Manufacturing Unit – 2002


Table of Content
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 The corrugated packaging industry in India Current trends in Indian corrugated packaging industry Future Developments Export Packaging Measuring Corrugated boxes Types of Flutes used in Corrugated Box Manufacturing Manufacturing process Imperative contacts in India

With high growth rates. oilcans. It started in a small way with box making units located only in Calcutta and Bombay and supplying boxes to users all over the country. Today there are a few thousand corrugated packaging units spread all over the country. armed for the future with both technology and perspective. However with consistent efforts this impression was rectified and advantages of this highly economical very flexible and high strength product were soon recognized in the market place. This acceptance led to the boom in the corrugated packaging sector. which were then converted to boxes by themselves and other smaller box makers who bought sheets from them. The Indian Industry continues to grow at a healthy pace with a strong involvement of the Federation. This was mainly due to a wrong perception of high cost and poor strength properties. soaps. Later a few manufacturers imported corrugating machines and started manufacturing corrugated sheets. with only the scoring. Infect even in those days corrugated boxes were mainly made using imported sheets from countries like Sweden.0 The corrugated packaging industry in India While the first unit for corrugated packaging in the world was set up as early as 1905. new box makers came in to set up box making capacity. It was then only a matter of time that the consumer goods like toothpastes. With surging demand. and hundreds of other items came to be dispatched in corrugated boxes. cutting and stitching being done here. the manufacturing process of corrugated box in India started only in the early fifties. However the acceptance of corrugated boxes as a substitute for wooden boxes or other conventional packaging was neither easy nor immediate. It was not unusual for boxes to be shipped from Bombay to Delhi.Report on Corrugated Box Manufacturing Unit – 2002 1. detergents. The growth of the industry was rapid from the late fifties through the early sixties. because of the thrust given to industrialization by the government after independence. . the industry soon spread geographically and took roots at manufacturing centers across the country and newer units came up in the vicinity of consuming centers and remote industrial towns.

pineapples.Kraft paper.Report on Corrugated Box Manufacturing Unit – 2002 2. innovatively designed point of purchase displays which also serve as transport cum consumer packs. Keeping in view the need for ecological balance. explosives etc. These demands have been successfully met by the corrugation industry through hard work and ingenuity. The corrugated packaging industry has been effectively and completely meeting the packaging requirements of the industry both for domestic needs and for exports. . the corrugated packaging industry has supported the development of non-conventional raw materials as well as the use of waste paper in the manufacture of its major raw material . the O-Pack for bulk packaging: bag-in-a-box. watermelons and vegetables. packages for electrodes. The industry is converting over 10 lakh tones of paper per year into boxes and boards. the corrugated packaging industry has been endeavoring to meet the challenging requirements of the future. Current trends in Indian corrugated packaging industry Today the corrugated industry is attracting more and more technocrat’s engineers and packaging specialists who are transforming it into a progressive and dynamic industry. boxes for horticultural produce like apples. Among the recent developments in the corrugated packaging are:  Surface coatings to give additional functional properties to paper. Recent advances With its progressive and dynamic outlook. New products and innovations in distribution and marketing systems have placed a demand on the corrugated packaging industry. oranges. besides making it from imported OCC as anywhere else in the world. film laminations for gloss and rub resistance. Indian paper industry has successfully made paper from sugarcane residue and recycling of local paper. Over 1 lakh people are directly employed in this industry belonging to the small-scale sector.

Corrugated packaging is also being ingeniously developed into point-of-purchase stands that find their place in super markets facilitating product displays and offering consumer convenience. Another recent advance is the development of standard dimension corrugated boxes for the use by courier companies in India. textiles and fabrics. shoes and other ordnance stores.  Multi colour printed white top boxes are the current trend in corrugated packaging. Corrugated boxes are being used for packing items like lanterns. . Die-cut boxes are being made in increasing numbers.  Among other products that will be increasingly packed in corrugated boxes are coffee beans.Report on Corrugated Box Manufacturing Unit – 2002  Another vital area where corrugated packaging has made a significant contribution is the packaging for defense. Non-packaging applications is a new trend. tea. Corrugated packaging has been innovatively used for making storage cabinets.  One new application is the use of weather resistant corrugated boxes for longterm storage of records and files. tobacco. processed foods. furniture partitions and other items. enamelled mugs.

A number of exciting developments are in the offering. grease. The industry is keeping pace with India's march towards modernization automation and computerization. In the years to come the industry structure is expected to undergo a sea change as the country moves towards globalization and liberalization. The current trend towards making of die cut boxes will accelerate and new designs will evolve. electricity etc. Research and development efforts are pursued relentlessly to place India on the world map of corrugated industry. The industry will develop precise printing of bar codes for automated identification. static.  Treated papers will be increasingly used to make the paper do more in terms of offering effective resistance to water. demanding closer tolerances and higher sophistication in corrugated packaging. storage and retrieval of corrugated boxes.Report on Corrugated Box Manufacturing Unit – 2002 3.  As automation will become the norm.  Use of F (micro) flute boxes for packaging of food products will be seen more The future trend will be towards 3 ply boxes. Users of corrugated boxes will install automatic packaging lines.  There will be increasing emphasis on recyclability and corrugated boxes will be required to conform to regulations on solid waste disposal. productivity per person will increase. inventory coding and enhanced aesthetics. Future Developments The future looks promising for the corrugated packaging industry. oil. This will help the industry to develop capability of international standards and thus opens the doors for export of corrugated boxes.  Brown boxes will give way to more attractive white top and other colour top corrugated boxes for in-built product segregation. The future will thus . The handling of corrugated boxes will also be automated and computerized in India. Composite materials will become obsolete and environment-friendly corrugated boxes will find greater use.

But some developed countries have very strict laws regarding the disposal of used paper. etc.  More use of printed corrugated shipping container and similar products with increase in use of colors and graphics will continue to find new applications especially in consumer-related products.  The future will also bring newer design concept such as display box-F flute boxes. material handling.  Computers are making their appearance felt all over the shop floor.Report on Corrugated Box Manufacturing Unit – 2002 witness corrugated packaging in India effectively competing in international markets. .  Corrugated boxes are the most widely accepted mode of packaging for export. quality assurance shall all soon involve a lot more of computer applications. bar coding-treated paper for different applications. Production.

has contributed significantly to the exports especially in the fields of fruits. processed foods. pharmaceuticals. Industry-wise consumption profile of corrugated packaging:(India) INDUSTRY Pharmaceutical Processed foods Fresh fruits/Vegetables Soaps/Cosmetics Beverages Distillery Tobacco/Cigarettes Textiles/Yarns PERCENTAGE 6% 19 % 2% 9% 2% 9% 3% 20 % . vegetables. The growth in exports of non-traditional items and the expansion of the corrugated packaging industry are both developments that are taking place almost simultaneously. In the years to come corrugated packaging will be a vital factor in ensuring India's increasing share in the world market. Export Packaging The recent trend in export is towards commodity packaging. There has been a lot of similarity in the pattern of development in both the fields. Corrugated packaging. One of the constraints faced by Indian exporters is the mode of packaging acceptable to international markets and it is here that the corrugated packaging plays a predominant role. It has been estimated that a significant increase in value realization can be achieved through the use of international quality packaging. and certain non-traditional items. designed to conform to international standards of strength and performance. textiles.Report on Corrugated Box Manufacturing Unit – 2002 4.

The break-up of this box production figure in terms of several important parameters can be presented below. Flute Wise Break up  85% is narrow flute .Report on Corrugated Box Manufacturing Unit – 2002 Electrical/Lamps Electronics Glass Engineering goods Consumer Durables Defense Miscellaneous TOTAL 2% 6% 2% 7% 8% 1% 4% 100 % Types of papers used by the corrugated packaging Industry: GSM 80 90 100 120 140 150 170 180 200 Others Percentage 5 2 27 22 14 15 1 9 2 3 Grade (BF) 14 BF or less 16 BF 18 BF 20 BF 22 BF 24 BF Duplex Imported Other Percentage 15 14 15 21 14 8 4 3 1 25 BF or more 5 The Indian Industry produces 10 lack tones of corrugated boxes annually.

Report on Corrugated Box Manufacturing Unit – 2002   5% is broad Flute 10% is micro flute Ply-wise break up      3% is 2 ply 28% is 3 ply 43% is 5 ply 21% is 3 ply 5% is 9 ply Type wise break up    80% boxes are of RSC type 15% boxes are Die-cut 5% boxes are other type Joint wise break up   95% boxes are stitch joint 5% boxes are glue joint .

Report on Corrugated Box Manufacturing Unit – 2002 Printing wise break up     70% boxes are printed by letterpress 20% boxes are printed by offset 5% boxes are printed by screen-printing 5% boxes are printed by flexo printing .

displays Light weight Strong alternative to paper board Superior printing surface Excellent for custom die cut boxes Uses: displays. The Width is the smaller dimension. point of purchase boxes B 49 1/8” E 95 1/16” . Measuring Corrugated boxes Without exception three dimensions always express the size of a corrugated cardboard box: Length. The Height is perpendicular to the opening. then width then height (also called depth). The Length is the larger dimension of the box's opening. 6. dairy Good puncture resistance Less space consumed in warehouse Uses: canned goods.Report on Corrugated Box Manufacturing Unit – 2002 5. furniture. Types of Flutes used in Corrugated Box Manufacturing Profile Flutes/foot Thickness Comments Flute C 41 11/64” Good stacking strength Good crushing resistance Very common material Uses: glass. These measurements refer to the inside dimensions of the box.

This board is ideal for making a strong box. Excellent for stacking heavy items! Triple Wall Corrugated Cardboard Composed of two layers of C flute and one layer of B flute. Double Wall Corrugated Cardboard Composed of a combination of B and C flutes.test Double wall-corrugated board should be used when stronger boxes and extra padding are needed. resistant to crush in storage and transit.Report on Corrugated Box Manufacturing Unit – 2002 Single Wall Corrugated Cardboard Available in a wide range of board strengths. test. . from 125 lb. test through 275 lb. Available in 200 lb. test through 500 lb.

supports. The combination of columns and arches produces a material far stronger than the paper. . C and E. There are four types of flutes. B. These flutes are known as A. containers. pads. Recently. partitions. cases. the paper now forms a row of columns. Because the corrugated board is very versatile packaging material. corrugated boards can be further converted to produce cartons.a basic structural form capable of supporting great weight. Fluted paper.Report on Corrugated Box Manufacturing Unit – 2002 7. dividers. stuck with another flat sheet of paper gets converted into 2-ply corrugated board. Corrugated Boards lend themselves to be cut to any shape and can be creased to fold in any direction. various styles of packaging are available. These are called flutes. boxes. 3-ply corrugated board has one fluted paper and two flat papers. and accessories such as interlockers. Kraft Paper or fluting media paper is passed through heated corrugated rolls to obtain continuous rolling. Horizontally. In a similar manner. Manufacturing process Corrugating is defined as the imparting of wave-like shape to a paper. 7-ply and 9-ply sheets are developed. flutes are arches-another basic structural form capable of providing cushioning properties. fillers etc. different types of flutes are used. wave-like shape. plates. These sheets are developed by converting multiples of flat papers and fluting media papers. Depending on the strength properties required. The entire gamut of shapes and forms are all collectively termed as 'corrugated boxes'. which provide internal cushioning and restrict movements. Thus. 5-ply. to suit the specific requirements. a new flute called as F flute has been developed. Vertically.

an international box code is assigned to each style. They anchor the contents within the outer box to arrest transit movement. The choice of proper box style depends on the product. Lastly to conclude the corrugated box manufacturing has its own technicalities but at the same time if proper technical personals are assigned along with efficient marketing and financial expertise it can be a profitable venture for Nirmal . The most popular style is the universal folding type because it is the most economical to manufacture and is adaptable to the packing of most end products. Some of the other popular styles are lock bottom. transport and storage requirements. its configuration and other packaging. 8.Report on Corrugated Box Manufacturing Unit – 2002 In order to standardize the nomenclature throughout the world. carry home. auto slot. known in industry as inherent fitments. Andheri (East) Mumbai 400 059 India Telephone: +91-22-850 0687. 3 M. corrugated boards are also used as inner fitments and accessories. In addition to functioning as transport containers. Vasanji Road. Mittal Industrial Estate No. They provide cushion and protect fragile articles during transit. 8504523 Facsimile: +91-22-850 4523 E-mail: admin@fcbm. and self-locking tray. Imperative contacts in India The Federation of Corrugated Box Manufacturers of India 138.

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