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Report on Corrugated Box Manufacturing Unit – 2002

INDUSTRY REPORT FOR NIRMAL TUBES AND CONTAINERS
PVT LTD
TOPIC: SETTING UP CORRUGATED BOX MANUFACTURING
UNIT IN INDIA
BY: BHARGAV SHAH

Table of Content

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

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

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

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

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

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

There has been a lot of similarity in the pattern of development in both the fields. 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. Report on Corrugated Box Manufacturing Unit – 2002 4. Corrugated packaging. designed to conform to international standards of strength and performance. vegetables. pharmaceuticals. 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. has contributed significantly to the exports especially in the fields of fruits. processed foods. Industry-wise consumption profile of corrugated packaging:(India) INDUSTRY PERCENTAGE Pharmaceutical 6% Processed foods 19 % Fresh fruits/Vegetables 2% Soaps/Cosmetics 9% Beverages 2% Distillery 9% Tobacco/Cigarettes 3% Textiles/Yarns 20 % . and certain non-traditional items. 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. textiles.

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

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

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

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

They anchor the contents within the outer box to arrest transit movement. transport and storage requirements. known in industry as inherent fitments. Report on Corrugated Box Manufacturing Unit – 2002 In order to standardize the nomenclature throughout the world. its configuration and other packaging. an international box code is assigned to each style. Andheri (East) Mumbai 400 059 India Telephone: +91-22-850 0687. carry home. 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 group. The choice of proper box style depends on the product. They provide cushion and protect fragile articles during transit. Some of the other popular styles are lock bottom.org . corrugated boards are also used as inner fitments and accessories. Mittal Industrial Estate No. Imperative contacts in India The Federation of Corrugated Box Manufacturers of India 138. 8504523 Facsimile: +91-22-850 4523 E-mail: admin@fcbm. auto slot. 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. In addition to functioning as transport containers. 3 M. and self-locking tray. Vasanji Road. 8.