Packaging Industry

Study of carton Box

Introduction
When you go to buy something, you might find yourself illogically getting drawn to
some products which you have not even tried earlier. If you analyses that you would
understand that the product is packaged in a style that appeals to your senses.
One of the main things about any product is its eye-catching packaging which makes it
stand out from other products. The definition of packing is given as a group of activities
that go into the planning of a product.

In this project we studied details the manufacturing of carton Box.

Cardboard boxes are industrially prefabricated boxes, primarily used for packaging goods and

materials. Specialists in industry seldom use the term cardboard because it does not denote a
specific material. The term cardboard may refer to a variety of heavy paper-like materials,
including card stock, corrugated fiberboard, and paperboard. 

Cardboard boxes can be readily recycled.

History of the Corrugated Box

 TheScottish-born Robert Gair invented the pre-cut cardboard or paperboard box in 1890 – flat pieces
manufactured in bulk that folded into boxes. Gair's invention came about as a result of an accident: he was
a Brooklyn printer and paper-bag maker during the 1870s, and one day, while he was printing an order of
seed bags, a metal ruler normally used to crease bags shifted in position and cut them. Gair discovered that
by cutting and creasing in one operation he could make prefabricated paperboard boxes. Applying this
idea to corrugated boxboard was a straightforward development when the material became available
around the turn of the twentieth century.
 Cardboard boxes were developed in France about 1840 for transporting the Bombyx mori moth and its
eggs by silk manufacturers, and for more than a century the manufacture of cardboard boxes was a major
industry in the Valréas area.
 The advent of lightweight flaked cereals increased the use of cardboard boxes. The first to use cardboard
boxes as cereal cartons was the Kellogg Company.
 Corrugated (also called pleated) paper was patented in England in 1856, and used as a liner for tall hats,
but corrugated boxboard was not patented and used as a shipping material until 20 December 1871. The
patent was issued to Albert Jones of New York City for single-sided (single-face) corrugated board. Jones
used the corrugated board for wrapping bottles and glass lantern chimneys. The first machine for
producing large quantities of corrugated board was built in 1874 by G. Smyth, and in the same year Oliver
Long improved upon Jones's design by inventing corrugated board with liner sheets on both sides. [  This
was corrugated cardboard as we know it today.
 The first corrugated cardboard box manufactured in the US was in 1895. By the early 1900s, wooden
crates and boxes were being replaced by corrugated paper shipping cartons.
 By 1908, the terms "corrugated paper-board" and "corrugated cardboard" were both in use in the paper
trade

Functions of Packaging

The most common functions of packaging are:

 Physical Protection- The product requires protection from many things like vibration, mechanical shock,
compressions, temperature, etc. Packaging serves the aim of protecting the product from all these factors.

 Transmit Information- Packages have labels that inform the product user on how to use, recycle, transport
or dispose of the product and the package. With certain products like pharmaceuticals, food, chemical
products, etc., this information on the packaging is required by the government also. Some labels and
packages can be used to track and trace as well.

 Marketing- The physical design and graphical design of the packaging of a product has been a vital
element used by marketers for decades to impress buyers in buying their products.

 Convenience- Certain packaging features can make a product convenient for use, distribution, handling,
display, opening, stacking, re-closing, reuse, dispensing, recycling and disposing of. For example, if there
is a straw provided with a ready-to-drink juice, one can easily take it around in cars and use and throw the
package.

 Barriers Protection- Many products require protection or barriers from water, dust, oxygen, vapour, etc.
In packaging, permeation is a critical factor. Products that need extended shelf life are often packaged
along with desiccants. In some food packages, a controlled or modified atmosphere is maintained. The
 primary function of packaging in such cases is to maintain a clean, sterile, fresh and safe environment for
the intended shelf life.

 Security- Packages can have superior tamper resistance so that tampering can be deterred. A
package could also have a tamper-evident feature so that one can make out if it has been tampered
with in transit or shipping. Such packaging features help in reducing security risks and package
pilferage.

Step by step process of corrugated industry

1.Raw Material Selection

The raw material for the corrugated industries is

1. Kraft paper

2. Pasting powder

3. Stitching wire
 4. Printing ink.

Based on the customer’s requirements the above items are procured in the
industry.

2. quality checking ( Incoming )

After receiving the raw materials the quality factors GSM and BF are tested for Kraft
papers with the help of the equipment GSM scale and Bursting Tester.

GSM Scale

GSM scale analog and Digital

 Bursting Tester

3. Corrugation

In this process the Kraft paper is converted in to two ply liner.

The output will be two ply liners.

4. Auto Sheet Cutting:

The two ply liner from the corrugation machine is feed to the sheet cutter.

Based on the dimension of the box the liner is cut. This machine is also used to cut the
top sheets.

5. Pasting:

In this process the liner and the top sheet are pasted together to form Board. Based on
the ply needed by the customer (3, 5, 7 ply) the no of liner pasted to the top varies.
6. Pressing:

The liner and the top pasted in the pasting machine are kept in the pressing machine to
give pressing to form board.

7. Creasing:

In this process based on the size of the box the impression are given and the edges of
the board are trimmed for its finishing.
8. Slotting:

In this process the creased board is slotted.

9. Punching:

In this process the creasing and slotting process are done together with help of tool
(die).Each box need separate die.
11. Stitching:

The slotted board is stitched together to form box

12. Inspecting:

The finished box is QC inspected before dispatch.

Indian Packaging Industry

The Indian packaging industry is growing at 14-15% annually.

This growth rate is expected to double in the next two years. •

According to the Indian Packaging Institute, Indian Packaging industry is USD 14 billion and growing at
more than 15% p.a.

These figures indicate towards a change in the industrial and consumer set up. •

The flexible packaging segment is estimated to be growing at over 35 percent annually. •

The industry is comprised of a large number of manufacturers of basic materials, converted packages,
machinery and ancillary materials. • Currently,

India is ranked 15th in the world for its paper and paperboard consumption and is expected to improve its
rank in the future. •

Paper is the fastest growing substrate segment with a growth rate of 6-7%.

The total demand for paper currently is estimated to be around 6 mn tones, of which about 40% is
consumed by the packaging industry.