Paper Boxes REPORT

Chapter 1

Preliminary physibility repory on Corrugated Kraft Paper Board Box

Corrugated Kraft Paper Board Box is the most popular shipping container, now-a-days. Corrugated Kraft Paper Board Box, technically called Corrugated Fibre Board Box is the most popular shipping container, now-a-days. The box is manufactured from corrugated board which consists of 3 or more layers of kraft paper. The middle fluted layer is pasted with two flat parallel sheets of paper. The boxes find their number of applications in the packaging of chemicals & drugs, tobacco, engineering goods, canned & bottled goods, food products, lamps, electrical appliances, glasswares etc.

Packaging plays a very important role in the country's economy. Till recently only the western world, more particularily the developed countries cared about proper packaging. However, now even developing countries like India have changed their outlook towards packaging and in the last few years increasing stress has been laid on improved and proper packaging. In fact, today, packaging is as important as the contents.

Corrugated boards were first produced in India in early fifties. Since then the production of Corrugated boards has increased steadily. Corrugated boxes have replaced wooden boxes & crates in many applications. Today, about 80% of all shipments in the world are being made in fibre board boxes. In India, about 60% of the packaging is being done with corrugated fibre board boxes.

Corrugated Board:-

Corrugated fibre board consists of a flat layer of paper sheet (liner) glued on one or both sides of a corrugated paper (medium). The corrugated board is made by passing two layers of paper (usually kraft) through corrugating machine. One layer of paper becomes corrugated after being passed thro' the heated rolls and other is brought into contact with it after the former having glued at tips.

The corrugating 'medium' is generally made from a 0.009" thick (9 caliper) or 0.23 mm. The glue frequently used is starch or silicate of soda adhesive. When only one liner is used, the product is known as "Single face" or "two ply" board. This board is flexible in one direction. When the corrugated medium is combined on both sides with flat sheets, it is known as double faced or "3-ply board".

Advantages of Corrugated Fibre Board Boxes :-

Corrugated fibreboard boxes have replaced the wooden and tin containers due to their several advantages for safe transportation of the goods. These are discussed here under :

Light in weight (freight advantage) Cellular structure with high compressive strength, resiliency & shock resistance. Assured

safety to delicate articles. Can be stored conveniently in folded condition when not in use, thus saving storage

space. Can be attractively printed, thus advertising advantage. By lining, lamination or coating, they can be made water resistant and resistant to other adverse conditions. Easy to fabricate. Contents packed in these boxes remain dust free. Available through out the year. .pa Expedites production due to one line conveyor packing. Re-usable No strapping necessary Desired in export market Eliminated dependency on natural wood.

Applications:-

Corrugated fibre board boxes are being used for the packing of industrial as well as consumer goods. They are used for packing of chemicals, drugs, tobacco, engineering goods, canned and bottled goods (such as Whisky, Beer, Soda, Drinking Water, Ketchups etc.), food, electrical appliances, confectionary, textiles, fruits, vegetables, potteries, footwear, glasswares and other fragile items, medical instruments, photographic equipments and a number of other products.

Some of the products where corrugated fibreboard boxes find extensive application are:-

1. Pharmaceuticals. 2. Glassware, crockery ware 3. Soaps & Cosmetics 4. Biscuits 5. Hosiery & ready made garments 6. Electronic products 7. Breweries 8. Cigarettes 9. Footwears 10. Toys 11. Milk products & other food items 12. Tea & Coffee 13. Automobile components

14. Rubber & rubber products 15. Engineering items and consumer durable like, TVs, Air Coolers, fans etc.16. Stationary items 17. Match boxes 18. Frozen fish 19. Apple, cherry, grapes etc. 20. Cashew nut industry .

Summary:-

The paper and paperboard industry has grown over the years to meet the ever-increasing need for paper as well as paperboard. This industry is more than a century old. Specific statistics are not available in respect of production in the small-scale sector. However, an important parameter for gauging the market potential for the products envisaged in this scheme is to ascertain the overall growth in the economy in general with particular reference to the growth of user industries that require corrugated board/boxes. A look at the user industries indicates that they have generally grown over the years and as per indications will continue to growth in the coming years as well. Consequently, the demand for corrugated paper board/boxes will also continue to be buoyant. A peculiar feature of this industry is that on the one hand there are several units in the large as well as small-scale sectors, which are sick and unable to function properly, while on the other-hand several units are flushed with orders and are working to capacity. An important factor for successful undertaking of corrugated paper board/boxes is the capacity to procure orders from bulk users on contract basis. Only large and regular orders will ensure stability to the unit. Through the market potential for these products can be considered to the fairly good, much will depend upon the marketing strategy adopted by an individual entrepreneur.

Total Project Cost:-

Cost of Land : 5.50 Building & Structures : 18.75 Machinery & Equipments : 25.27 Misc. Fixed Assets : 4.85 Preliminary & Preoperative expenses : 4.41 Contingencies/Price- escalation : 1.10 Margin Money for Working Capital : 10.59

___________

Total : Rs. 70.46 Lakhs

Chapter 2

Various SSI to be benchmark

Lamba Packaging IndustriesPlot No. 127-128, Sector-3 Industrial Growth Centre, Bawal, Distt. Rewari (HARYANA), INDIA Phone : 09254304789, 09215756557, 09215756558 01274-657855 E-mail : [email protected]

J.K. ENTERPRISES(Manufacturers of Corrugated and Printed boxes.) Plot No. 434, Phase-IV, Udyog Vihar, Gurgaon (HR.)

PACKING CONCEPTS(Manufacturers of Corrugated and Printed boxes.)Plot No. 115-B, Sector-7, IMT Manesar, Gurgaon ( HR.)

Amit Packaging IndustriesNo. 109, Sector-7, IMT Manesar, Gurgaon, Haryana - 122 050, IndiaGurgaon0124 4368200

Dau`s Packaging IndustriesPlot-137, Daulatabad Road, Industrial Area, B/H Bhalla Chemicals, Industrial AreaGurgaon09811624449

Kiran Packaging IndustriesPlot No. 110, Sector - 24 Faridabad, Haryana - 121 004 0129 4061090

Vinveet Packaging Industries12/1, Mathura Road, Mathura RoadFaridabad0129 2270817

Jai Packaging IndustriesNarsinghpurNational Highway 8, Sector 36, Gurgaon09871889997

mailto:[email protected]

Thermo Packing IndustriesPlace No 375, Sector 6, Sector 6Faridabad0129 2241674

Vijay Packaging Industries47, 48, Surat Nagar, Daulatabad Road, Near Railway Crossing, Gurgaon, Haryana 122001India09810236594

Chapter 3Visit of three SSI

Sky Export packaging Plot no-131 , Sector-6 Industrial Growth Centre, Bawal, Distt. Rewari (HARYANA),Website - www.skypackindia.inTelefax:- +91-129- 3220741,Mobile +91-9811347100,+91-9310727249Email [email protected] [email protected]

Sky Packaging Industries. is a professionally managed organization, located in the City of India. Incepted in the year 1996, the company is managed under the guidance of the CEO, Mr. Satish kumar. He has worked at managerial level in packaging industries in India has introduced new innovative ideas for managing production and maintaining quality practices. We offer a wide variety of industrial packaging material such as Wooden Boxes, Wooden Pallets, Pallet Boxes,Ply boxes, All Type Corrugated boxes. and many more. The effect of rich technical expertise is easily visible in all our products. Additionally, we are in the process to attain ISO 9001-2008 certificate. Below, we have mentioned few features of the organization that depicts our strength and possibility of growth in Indian market

Name of the CEO Mr. Satish kumar

Establishment Year 1996

Primary Business Type Manufacturer, Supplier & Service Provider

Annual Sales(in Rs.) 1 crore

Number of Employees 20 to 25

Market Covered Domestic and international

S.No Machine Name Specification Quantity

1 Corrugation Machine 52" Narrow Flute (Flute Profile B) 1

2 Corrugation Machine 52" Narrow Flute (Flute Profile E) 1

3 Automatic Sheet Cutter Sheet Cutter /Paper Cutter/ Role Cutter 55" 3

4 Manual Board Cutter 58" x 68" 1



7 Pasting Machine 72" 2

8 Pasting Machine 52" 1

9 Pressing Machine 65" x 75" 1



http://www.skypackindia.in/

10 Automatic Die Punching Machine 50" x 70" 1

11 Automatic Die Punching Machine 28" x 40" 1

LAMBA PACKING INDUSTRIESPlot No. 127-128, Sector-3 Industrial Growth Centre, Bawal, Distt. Rewari (HARYANA), INDIA Phone : 09254304789, 09215756557, 09215756558 01274-657855 E-mail : [email protected]

Lamba Packing Industries pride in being one of best corrugated box making facility in this part of the globe. A dedicated team for manuftheacturing and quality assurance personnel at Lamba Packing Industries ensures timely supplies and quality that invariably exceeds client expectation.This commitment is amply proven by the fact that a multi national client of ours is continuously sourcing their requirement of corrugated boxes from us throughoutthe last two decades. At Lamba Packing Industries, we believe in building lasting relationships with our valued clients. This becomes possible only with our understanding of client requirements and fulfilling them. We are capable of making corrugated boxes for any application to the clients complete satisfaction.We take pride in introducing ourselves as one of the country's leading manufacturers of corrugated boxes and unit boxes. In fact we specialize in providing total packaging solutions.We manufacture corrugated boxes and provide packaging solutions to our multi, national and corporate clients to their complete satisfaction. Our Quality Consciousness has made our products match the best international standards. Our customer-centric approach towards the business is proven by our customers' confidence in us. Not only our sales to different customers has been consistently increasing our share of their purchase from different packaging vendors is invariably at number one. It makes us proud that some of our customers procure 1000/0 of their packaging requirement from us. Our sale has been consistently increasing and has reached over Rs.6 Crores PA.We ensure 24 X 7 manufacturing and delivery schedules, as we fully understand the criticality of packaging for any manufacturing organization The biggest Die Cutting Machine in the Industry to ensure accurate sizing. Company owned trucks to ensure schedule adherence. In-house design development and printing. Bulk purchases of paper and other raw materials directly from the mills and

manufacturing units with the aim to pass the resultant cost saving to our clients. Special treatment of all types of papers with a combination of specially imported

chemicals to make the cartons highly water resistant. Substantial Captive Power provisions to counter any power shortage situation. Own in house gum making plant to ensure quality. Semi Automatic Gluing Machine for making staple-less cartons. Fully Equipped Testing Laboratory

We are fully equipped to manufacture and deliver various types of corrugated boxes as per the client's requirements. Some of the products we specialize in are:

Master Cartons Mono Cartons Corrugated Pallets Shipping Containers Die Cut Items Displays Point of Purchase Packaging Partitions Interior Packaging Storage Bins Adjustable Depth Book Folds Ring Flaps Unit Cartons

Wooden Boxes and Pallets

Infrastructure

The company has a well-equipped and sophisticated infrastructure facility to manufacture premium quality products for its customers. It has state-of-the art- manufacturing unit with modern and unique production equipments and industrial testing machines. It has dedicated team of highly qualified engineers who contribute with innovation into the manufacturing, production, maintenance, quality control and servicing departments of the company.We have two Industrial Material Lifts for easy movement of raw and finished materials.We make every effort to make our complete manufacturing process completely Eco Friendly to preserve Mother Nature.Company owned fleet of trucks to meet delivery schedules.We maintain regular inventory of raw and finished materials to meet customer requirements.

Quality is assured through a well-equipped laboratory manned by qualified and trained staff dedicated for this purpose. Every manufacturing input has to go through a stringent quality inspection before it is pressed into production.

Machines-

2 Nos. Corrugation Machines with 47" and 52" with flute attachments A and B capable of processing all types of Indian and Imported papers.

1 No. Motorized Sheet Pressing Machine.

4 No. Stitching Machines ( all motorized). Two 48", One 42", Three 44" (computerized) Double Pin and One 62" Double Pin. (Capable of stitching cartons up to 92" in height.

2 Nos. Four Bar Rotary Machines (all motorized) for creasing and Cutting of corrugated sheets.

3 Nos. Board Cutters for cutting corrugated rolls and papers in different Size.

1 No. Single Color Flexo Printing Machine (size 75" X 100").

3 Nos. Pasting Machines (all motorized) one each of 72" and 86" and three of 120". Processing capacity 3000 sheets of7 Ply in 8 hours.

2 Nos. Die Cutting Machines. Size 45" X 66" and 68" X 105". The latter is the biggest machine in the industry and is capable of accurately cutting cartons for refrigerators, washing machines, and heavy duty refrigeration and air conditioning units.

1 No. Semi Automatic Gluing Machine.

2 Nos. Power Slotters motorized 86" and 72" for slotting any size.

Auto Sheet Cutter

1 No. Partition Cutter motorized for making partitions.

2 Nos. Power Cutters for cutting and packaging maximum thickness and Size.

1 No. Creasing Machine manually operated to make front covers.

1 No. Semi Automatic Gluing Machine (size 48"). For making stitch less cartons.

Complete Gum making plant for internal usage.

1 No. Manual Slotter for use during emergency.

2 Nos. Diesel Generators for uninterrupted captive power generation.

Computers, Laser Printers, Color Printers, Scanners and Xerox Copiers for In House Designing.

Cargo International Packagings technolog

Mr. Raj Kamal Jindal (Managing Director)1418-20, HSIIDC Industrial Estate Rai, SonepatSonipat, Haryana - 131 029, India Telephone:+(91)-(130)-6991036

Established in the year 1983, we, Cargo International Packagings are recognized amongst the renowned manufacturers and exporters of a vast assortment of Corrugated Packaging Cartons and Corrugated Packaging Boxes. Our range includes Corrugated Carton Boxes, Master Cartons, Mono Cartons, Duplex Board Cartons, Grey Board Cartons and Two Piece Boxes. Further, we also offer Corrugated Board Trays, Pizza Boxes and Interlock Pattern Cartons. These are made by converting tones of kraft paper into boxes with the help of automatic in line 3/5 ply corrugated plant. Our range finds applications in retail sector, FMCG sector, corporate houses & manufacturing & export companies and is known for its light weight, high holding capacity & durability.

Being an ISO 9001-2008 certified organization; we follow a quality oriented approach while manufacturing our range. Designed as per the industry standards, all the boxes are regularly tested on certain parameters by our quality inspectors. We are backed by a sophisticated manufacturing unit, testing laboratory and a double story factory that allow us to offer a quality assured range to our clients.

Our rich industry experience, sound infrastructure, client centric operations, such as customization, prompts deliveries and competitive rates and transparent business dealings have earned us numerous awards and memberships. This has also earned us a huge client base across the country. We have M/s. Britannia Industries Ltd., M/s. Glaxo Smithkline Consumer Healthcare Ltd.??? M/s. SKOL Breweries and M/s. Pepsi Foods Pvt. Ltd. as our major clients.

Basic InformationBusiness Type ManufacturerOwnership & CapitalYear of Establishment1983Trade & MarketAnnual Turnover - Rs. 4-40 Crore Approx.Team & StaffTotal Number of Employees -51 to 100 People

InfrastructureWe have an added advantage of time saving & prompt delivery due to our latest automatic in line 3/5 Ply corrugated plant which converts 1500 tones of Kraft paper into corrugated cartons. This Is an additional plant to our functional semi auto line plant. Our manufacturing plant has the capacity to deliver goods to our customers on the same day on the placement of orders. Our endeavor Is to provide Quality, Reasonable Price, Quick Delivery and Performance as per claims. We have our own fleet of carriers that help us in quick & direct delivery at destinations throughout the country.

3 ply Corrugation Plant 1.6 mtr. Narrow & Broad Flute 2 color Printer, Slotter and Die Cutter 2500 x 1600 mm Chain feeder Single color Printer, Slotter and Die Cutter 2400 x 1200 mm Auto Lead Edge Feeder

with Speed of 120 sheet Per Minute Single color Printer and Slotter 2400 x 1600 mm Chain Feeder. Auto side Flap Pasting Machine 900 mm with Auto Packing (Bundling) Machine. Stitching Machine 30” - 6 nos Fully Auto Bed Die Cutter Mono Carton Flap Pasting Machine – 2 Nos.

Chapter 4Compair and analysis various cost factor

Total Project Cost:-Cost of Land : 5.50

Building & Structures : 18.75

Machinery & Equipments : 25.27

Misc. Fixed Assets : 4.85Preliminary & Pre-

operative expenses : 4.41

Contingencies/Price- escalation : 1.10 Margin Money for Working Capital : 10.59 __________________

Total : Rs. 70.46 Lakhs __________________ Annual Profitability (at 60% efficiency, 1st year):- a) Annual Sales Revenues : Rs.175.50 Lakhs b) Net Profit : Rs. 10.47 Lakhs

Basis & Presumptions:- No. of working days/year : 300 No. of shifts/day : Single No. of working hours/shift : 8 Product(s) Mix,Capacity & Its Utilisation:- Finished Product(s) : Corrugated Kraft Paper Boxes Average Selling Price : Rs.32,500 per ton Annual Installed Capacity : 900 tons Selling price : 32.5 rupees/kg

Plant & Machinery:- Following plant, machinery and equipment are required for the proposed project:-_____________________________________________________________S.No. Description Qty. Rate Amount (Rs.Lakhs)_____________________________________________________________ A. Corrugating Unit 1. Single Face Corrugating M/c 1 3.00 3.00 2. Slitting Attachment with cutter 1 0.18 0.18 3. Board Cutter, 62” x 62” 1 0.26 0.26 4. Sheet Pasting Machine 1 0.44 0.44 B. Box Making Unit

1. 4-Bar Rotary Cutting & Creasing M/c, 95” 1 1.95 1.95

2. Eccentric Slotter, 42” 1 1.95 1.95 3. Partition Slotter, 42” 1 0.45 0.45 4. Stitching Machine, 30” 1 0.25 0.25 5. Stitching Machine, 36” 1 0.30 0.30 6. Vertical Bending Machine, 72” 1 1.40 1.40 7. Single Slotting Machine, 12” 1 0.15 0.15 C. Printing Unit 1. Multi-colour Offset Printing M/c 1 10.00 10.00 2. Screen Printing Equipment 1 0.50 0.50 D. Testing Equipment 1. Brusting Strength Factor Tester 1 0.30 0.30 2. Graqmmage Tester 1 0.05 0.05 3. Compression Strength Tester 1 1.50 1.50 4. Puncture Resistance Strength M/c 1 0.30 0.30 _____________________________________________________________ Rs..22.97 Lakhs

Cost of installation, erection, commissioning Taxes, Freight Insurance etc. 10% Rs.. 2.30 Lakhs

_____________________________________________________________

Total Rs. 25.27 Lakhs_____________________________________________________________

Misc. Fixed Assets:-

Additionally, following misc. fixed assets are required for the proposed project:- (Rs.Lakhs) a. Standby Gen Set, 40 KVA : 2.25

b. Electrification Expenses and Electrical Equipments : 0.75

c. Weighing Machine : 0.20 d. Maintenance Tools & Equipment : 0.05 e. Office Furniture & Equipment : 0.75 f. Fire Fighting & Other Safety Equipments : 0.50 g. Delivery Rickshaw : 0.10 h. Misc. : 0.25 __________________

Total Rs. 4.85 Lakhs

__________________

Chapter -5Selection of best machines,process, technique

Corrugated Kraft Paper Board Box, technically called Corrugated Fibre Board Box is the most popular shipping container, now-a-days. The box is manufactured from corrugated board which consists of 3 or more layers of kraft paper. The middle fluted layer is pasted with two flat parallel sheets of paper. The boxes find their number of applications in the packaging of chemicals & drugs, tobacco, engineering goods, canned & bottled goods, food products, lamps, electrical appliances, glasswares etc. Packaging plays a very important role in the country's economy. Till recently only the western world, more particularily the developed countries cared about proper packaging. However, now even developing countries like India have changed their outlook towards packaging and in the last few years increasing stress has been laid on improved and proper packaging. In fact, today, packaging is as important as the contents. Corrugated boards were first produced in India in early fifties. Since then the production of Corrugated boards has increased steadily. Corrugated boxes have replaced wooden boxes & crates in many applications. Today, about 80% of all shipments in the world are being made in fibre board boxes. In India, about 60% of the packaging is being done with corrugated fibre board boxes.Manufacturing process:- The process of manufacture of corrugated fibreboard & boxes is quite simple. The unit mainly comprises of two sections viz. corrugated board making and box making section. Manufacture of corrugated board Corrugated board is made of a corrugated paper sheet of paper glued to the facings of flat-paper, usually kraft. A corrugating machine is employed for the corrugation of flat sheet and preparation of corrugated flexible 2 ply board. The machine is called as single-face corrugating machine. One layer of paper becomes corrugated after passing through the heated fluted rolls and the other is brought in contact with the former having been glued at the tips. These two sheets get pasted together and are wound in rolls. The resulting roll is known as single face or 2-ply corrugated board. By cutting this roll with board cutter machine; glueing the corrugated side on pasting machine & then placing 3rd ply of paper over it, double face or 3-ply corrugated board is produced. Similarly, board to board can be pasted to form thicker boards i.e. 5-ply, 7-ply and 9-ply boards. Manufacture of boxes:- The corrugated board produced as above is dried (for drying of glue) and may now be processed further to produce-corrugated boxes. The size of a box is always given in terms of the inside dimensions, with the longer dimension (length) of the opening given first followed by width and depth. The most economical box for a given cubic contents has the proportions of 2:1:2 (L:W:D). However, other proportions may also be used. For manufacturing boxes of any particular dimensions, it is first decided as to how the blanks for the boxes should be cut to minimise the wastage. Calculation of Weight of a Box:- Weight of the box is equal to area of the sheet multiplied by weight/cu.m. the sheet.

Area of sheet (i) Length of the sheet required, 'a'

= 2L + 2W + 2 inches. (ii) Width of the sheet required 'b' = W + H Where L = Length of the box W = Width of the box H = Height of the box 2" is the stitching margin. Weight/sq.m. of sheets : It will depend upon the number of plies & g.s.m. (grams/sq.m.) of paper. For the corrugating media, on an average 45% extra material is consumed compared with the plain one depending upon the size of flute. So, weight per sgm. of a 3 ply board would be as follows :- gsm of top liner +(1.45 x gsm of media) + gsm bottom liner. Fabrication of Boxes: The various steps involved in the fabrication of corrugated fibre board boxes are: Slitting & creasing; slotting; flap or corner cutting and stitching or gluing. simultaneously carried over a rotary cutting & creasing machine. The trimmed and creased sheet is slotted and flap out on an eccentric slotter. Finally, it is either stitched using stiching machine or glued/taped manually. The boxes are shiped in the form of flat tube which is set up and closed by the packer. Printing: There are different methods of printing the corrugated boxes. Some of the small scale manufacturers are printing the boxes after fabrication, by the technique of screen printing. However, printing can be done in a printer slotter machine. In this machine, the blanks are printed using soft rubber dies and the body score or vertical score and slots are introduced in the board. Printing can also be performed on the paper sheet, before making corrugated sheet/board.The layer of paper which will come outside of the box, is printed on flexographic machine

PROCESS FLOW CHART

Chapter 6References

klpackaging.indiacon.com/Packaging

www.manta.com/c/mmb5pyl/craft-corrugated-box-inc

www.alibaba.com/showroom/corrugated-craft-box.html

www.made-in-china.com › Quick Products

www.boxkraft.co.nz/

www.craftscotland.org/

www.corrugatedboxesindia.com/

klpackaging.indiacon.com/Packaging

www.indiamart.com › ... › Packaging Bags

www.skypackindia.in

http://www.skypackindia.in/

http://www.google.co.in/url?url=http://dir.indiamart.com/indianexporters/plastic-bags.html&rct=j&sa=X&ei=pcaXT--OBca4rAfUkZ3JAQ&ved=0CIIBEOkFKAAwBA&q=corrugated+craft+box+report&usg=AFQjCNGDCq2GRwvPRaDYuIzb4s24fxyG0Q

http://www.corrugatedboxesindia.com/

http://www.craftscotland.org/

http://www.boxkraft.co.nz/

http://www.google.co.in/url?url=http://www.made-in-china.com/quick-products/&rct=j&sa=X&ei=xcWXT8K4GIfyrQfGpKjEAQ&ved=0CGkQ6QUoADAE&q=corrugated+craft+box&usg=AFQjCNE-RUfT1Uioq0W9VJcoBQWPar7-SA

http://www.alibaba.com/showroom/corrugated-craft-box.html

http://www.manta.com/c/mmb5pyl/craft-corrugated-box-inc

lambapackingindustries.com

Paper Boxes REPORT

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