PROJECT REPORT

ON

CORRUGATED BOXES
Introduction
Industrially pre-fabricated boxes are primarily used for packaging goods and materials.
It is one of the fast growing industries in all over India and also in our state. The
business has witnessed a significant jump in the last decade because of huge growth in
processed food, fruits and vegetables, electronic and consumer durables industries.

Market : India is the world's third largest apple producing country only behind China
and the United States. The major portion of the produce comes from our state.
However, rude packaging in wooden boxes is telling upon the industry that forms the
back bone of the state's economy.
Other states where apples are grown are using corrugated cardboard boxes. However,
most of growers in Jammu and Kashmir still use wooden boxes to pack the fruit, even
as the trend has started shifting. The packaging tool has turned out to be the most
popular goods transporting container. Industry experts in the state are of the view that it
will soon become indispensable for the Rs.4,500 cr horticulture industry of Jammu and
Kashmir, which houses Asia's second largest fruit market and employs thousands of
farmers and people related to the sector.
Corrugated board boxes are also used in different area of packing in goods such as:
Breweries, Glass wares, Cigarettes, Pharmaceuticals, Biscuits, Milk & Milk products,
Soaps, Cosmetics, Tea & Coffee, Hosiery, shoe & footwear industry, toys etc.

Opportunities
It's a huge industry and growing: Corrugated packaging is a Rs.2 billion a year industry
in India. In another five years, over 90 percent of all products in India would be delivered
or displayed in corrugated. It is an industry that will survive well into the next century,
and beyond. It's everywhere and everybody needs it: People outside the state have
occupied the space but in Jammu and Kashmir the vacuum remains unfilled. Everybody
wants it because it is cost effective, lightweight, functional, versatile and sustainable.
Corrugated is "green": Corrugated is the most recovered form of packaging, with 91
percent of all containers produced being reclaimed for recycling.

Advantages of Corrugated Fibre Board Boxes :-

Corrugated fiber board boxes have replaced the wooden and tin containers due to their
several advantages for safe transportation of the goods. These are discussed here
under;
1) Light in weight (freight advantage)
2) Cellular structure with high compressive strength, resiliency & shock resistance.
Assured safety to delicate articles.
3) Can be stored conveniently in folded condition when not in use, thus saving storage
space.
4) Can be attractively printed, thus advertising advantage.
5) By lining, lamination or coating, they can be made water resistant and resistant to
other adverse conditions.
6) Easy to fabricate.
7) Contents packed in these boxes remain dust free.
8) Available through out the year.
9) Expedites production due to one line conveyor packing.
10) Re-usable
11) No strapping necessary
12) Desired in export market
13) Eliminated dependency on natural wood.

Types of corrugated board:

1. Single face/two ply
2. Single wall/3-ply
3. Double wall/5-ply
4. Triple wall /7-ply

BASIS AND PRESUMPTIONS:

1. Single shift of 8 hours a day, 25 days a month and 300 days in a year is presumed.
Efficient machines and workers are also presumed.
2. Minimum 2 year period is considered for achieving full capacity utilization
3. Labour rates are as per the prevailing rates.
5. The estimates are drawn for a production capacity generally considered techno-
economically viable for model type of manufacturing activity.
6. The information supplied is based on a standard type of manufacturing activity viable
for model type of manufacturing activity.
7. The information supplied is based on a standard type of manufacturing activity
utilizing conventional techniques of production at optimum level of performance.
8. Costs in machinery and equipment, raw materials and the selling prices of the
finished products etc., are generally prevailing at the time of preparation of the project
profiles and may vary depending upon various factors.
.

IMPLEMENTATION SCHEDULE:
Normally 1 year is required for the complete implementation of the project,
including machinery 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 two paper reels are run together, one layer of paper becomes
corrugated after passing through the heated rolls 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/ corrugated roll/board. By
cutting this roll with board cutter and then gluing the corrugated side by a pasting
machine and placing 3rd ply of paper over it double faced or 3-ply corrugated board is
produced, this board is kept under pressure in a sheet pressing machines for some time
for setting of the wet glued sheets. Similarly board 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 Cutting
ii) Creasing
iii) Slotting
iv) Flap or Corner Cutting
v) Stitching
After passing the sheet through these operations, a box or container is ready,
slitting and creasing operations can simultaneously by carried over a 4 bar rotary cutting
and creasing machine. The trimmed and creased sheet is slotted and flap cut on an
Eccentric Slotted Machine. Finally, it is either stitched over a stitching machine or
glued/taped manually.
For partition boxes the half slotted boards are used which can conveniently be produced
over a partition spotter machines.

III. LAND AND BUILDING

1 Land leased
2 Building - - Office - 200 sq. ft. ----
Go-down - 3000 sq. ft. ----
Production Area - 3800 sq. ft. ----
Total - 6000 sq. ft. ----

IV. PLANT AND MACHINERY

1 Single face paper corrugation Machine
2 Two Board Cutters with one reel stand light
model
3 One Sheet Pasting Machine
4 One sheet pressing
5 One 4-Bar Rotary Cutting & Creasing
6 One Eccentric Slotted
7 Two stitching machines
i) One 36” arm angular head
ii) One 48” arm, straight head
Packing, forwarding, excise, insurance, sales-
tax, freight etc.
Office furniture
Erection and electrification
Total Capital Cost Rs. 70.00 lakh
a) Land Owned/Leased/Hired
b) Building (5800sq.ft) Rs. 30.00 lakh
c) Machinery/ Equipment’s Rs. 40.00 lakh

Operational Cost (For 1 Month) Rs.10.00 lakh

Grand Total Rs. 80.00 lakh

5. Suppliers;
Registered dealers of
Equipment
Machinery
Raw materials

6. Buyers
Dealers
Manufacturing units
Packaging units
Exporters of fruits like apple, strawberry and walnut