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

Report on Corrugated Box Manufacturing Unit – 2002

1.0 The corrugated packaging industry in India

While the first unit for corrugated packaging in the world was set up as early as 1905, the

manufacturing process of corrugated box in India started only in the early fifties. 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. It was not unusual for boxes to be shipped

from Bombay to Delhi.  Infect even in those days corrugated boxes were mainly made

using imported sheets from countries like Sweden, with only the scoring, cutting and

stitching being done here. 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.

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.

However the acceptance of corrugated boxes as a substitute for wooden boxes or other

conventional packaging was neither easy nor immediate. This was mainly due to a wrong

perception of high cost and poor strength properties. 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. It was then only a matter of

time that the consumer goods like toothpastes, soaps, detergents, oilcans, and hundreds of

other items came to be dispatched in corrugated boxes.

This acceptance led to the boom in the corrugated packaging sector.  With surging

demand, new box makers came in to set up box making capacity.  With high growth

rates, 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. 

Today there are a few thousand corrugated packaging units spread all over the country. 

The Indian Industry continues to grow at a healthy pace with a strong involvement of the

Federation, armed for the future with both technology and perspective.

Report on Corrugated Box Manufacturing Unit – 2002

2. 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.

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. The corrugated packaging industry has been effectively and completely meeting

the packaging requirements of the industry both for domestic needs and for exports.

Keeping in view the need for ecological balance, 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 - Kraft paper. Indian paper industry

has successfully made paper from sugarcane residue and recycling of local paper, besides

making it from imported OCC as anywhere else in the world.

Recent advances

With its progressive and dynamic outlook, the corrugated packaging industry has been

endeavoring to meet the challenging requirements of the future. New products and

innovations in distribution and marketing systems have placed a demand on the

corrugated packaging industry. These demands have been successfully met by the

corrugation industry through hard work and ingenuity.

Among the recent developments in the corrugated packaging are:

Surface coatings to give additional functional properties to paper; film

laminations for gloss and rub resistance; innovatively designed point of purchase

displays which also serve as transport cum consumer packs; the O-Pack for bulk

packaging: bag-in-a-box; boxes for horticultural produce like apples, oranges,

pineapples, watermelons and vegetables; packages for electrodes, explosives etc.

Report on Corrugated Box Manufacturing Unit – 2002

Another vital area where corrugated packaging has made a significant

contribution is the packaging for defense. Corrugated boxes are being used for

packing items like lanterns, enamelled mugs, processed foods, shoes and other

ordnance stores.

Among other products that will be increasingly packed in corrugated boxes are

coffee beans, tea, tobacco, textiles and fabrics. Non-packaging applications is a

new trend. Corrugated packaging has been innovatively used for making storage

cabinets, furniture partitions and other items.

Multi colour printed white top boxes are the current trend in corrugated

packaging. Die-cut boxes are being made in increasing numbers. 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.

One new application is the use of weather resistant corrugated boxes for long-

term storage of records and files. Another recent advance is the development of

standard dimension corrugated boxes for the use by courier companies in India.

Report on Corrugated Box Manufacturing Unit – 2002

3. Future Developments

The future looks promising for the corrugated packaging industry. A number of

exciting developments are in the offering. Research and development efforts are

pursued relentlessly to place India on the world map of corrugated industry. The

industry is keeping pace with India's march towards modernization automation and

computerization. This will help the industry to develop capability of international

standards and thus opens the doors for export of corrugated boxes.

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.

There will be increasing emphasis on recyclability and corrugated boxes will

be required to conform to regulations on solid waste disposal. Composite

materials will become obsolete and environment-friendly corrugated boxes

will find greater use.

Treated papers will be increasingly used to make the paper do more in terms

of offering effective resistance to water, grease, oil, static, electricity etc.

Brown boxes will give way to more attractive white top and other colour top

corrugated boxes for in-built product segregation, inventory coding and

enhanced aesthetics.

Use of F (micro) flute boxes for packaging of food products will be seen more

The future trend will be towards 3 ply boxes.

As automation will become the norm, productivity per person will increase.

Users of corrugated boxes will install automatic packaging lines, demanding

closer tolerances and higher sophistication in corrugated packaging. The

handling of corrugated boxes will also be automated and computerized in

India. The industry will develop precise printing of bar codes for automated

Report on Corrugated Box Manufacturing Unit – 2002

identification, storage and retrieval of corrugated boxes. The future will thus

witness corrugated packaging in India effectively competing in international

markets.

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, bar coding-treated paper for different applications, etc.

Corrugated boxes are the most widely accepted mode of packaging for export.

But some developed countries have very strict laws regarding the disposal of

used paper.

Computers are making their appearance felt all over the shop floor.

Production, material handling, quality assurance shall all soon involve a lot

more of computer applications.

Report on Corrugated Box Manufacturing Unit – 2002

4. Export Packaging

The recent trend in export is towards commodity packaging. It has been estimated that a

significant increase in value realization can be achieved through the use of international

quality packaging. 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. There has been a lot of similarity in the pattern of development in both

the fields.

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.  Corrugated packaging, designed to conform to international standards of strength

and performance, has contributed significantly to the exports especially in the fields of

fruits, vegetables, textiles, processed foods, pharmaceuticals, and certain non-traditional

items.  In the years to come corrugated packaging will be a vital factor in ensuring India's

increasing share in the world market.

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 %

Report on Corrugated Box Manufacturing Unit – 2002

Tobacco/Cigarettes 3 %

Textiles/Yarns 20 %

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

Report on Corrugated Box Manufacturing Unit – 2002

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. 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

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

Report on Corrugated Box Manufacturing Unit – 2002

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

Report on Corrugated Box Manufacturing Unit – 2002

5. Measuring Corrugated boxes

Without exception three dimensions always express the size of a

corrugated cardboard box: Length, then width then height (also

called depth).

These measurements refer to the inside dimensions of the box.

The Length is the larger dimension of the box's opening.

The Width is the smaller dimension. The Height is

perpendicular to the opening.

6. 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, furniture, dairy

B 49 1/8” Good puncture resistance

Less space consumed in warehouse

Uses: canned goods, displays

E 95 1/16” Light weight

Strong alternative to paper board

Superior printing surface

Excellent for custom die cut boxes

Uses: displays, point of purchase boxes

Report on Corrugated Box Manufacturing Unit – 2002

Single Wall Corrugated Cardboard

Available in a wide range of board

strengths, from 125 lb. test through 275 lb.

test.

Double Wall Corrugated Cardboard

Composed of a combination of B and C

flutes.

Available in 200 lb. test through 500 lb.test

Double wall-corrugated board should be

used when stronger boxes and extra

padding are needed.

Excellent for stacking heavy items!

Triple Wall Corrugated Cardboard

Composed of two layers of C flute and one

layer of B flute.

This board is ideal for making a strong box,

resistant to crush in storage and transit.

Report on Corrugated Box Manufacturing Unit – 2002

7. Manufacturing process

Corrugating is defined as the imparting of wave-like shape to a paper. Kraft Paper or

fluting media paper is passed through heated corrugated rolls to

obtain continuous rolling, wave-like shape. These are called

flutes.

Vertically, the paper now forms a row of columns- a basic structural form capable of

supporting great weight. Horizontally, flutes are arches-another basic structural form

capable of providing cushioning properties. The combination of columns and arches

produces a material far stronger than the paper.

Depending on the strength properties required, different types

of flutes are used. There are four types of flutes. These flutes are

known as A, B, C and E. Recently, a new flute called as F flute

has been developed. 

Fluted paper, stuck with another flat sheet of paper gets

converted into 2-ply corrugated board. 3-ply corrugated

board has one fluted paper and two flat papers. In a similar

manner, 5-ply, 7-ply and 9-ply sheets are developed. These

sheets are developed by converting multiples of flat papers and fluting media papers.

Corrugated Boards lend themselves to be cut to any shape and can be creased to fold in

any direction. Thus, corrugated boards can be further converted to produce cartons,

boxes, cases, containers, and accessories such as interlockers,

partitions, dividers, pads, plates, supports, fillers etc. which

provide internal cushioning and restrict movements.

The entire gamut of shapes and forms are all collectively termed as 'corrugated boxes'.

Because the corrugated board is very versatile packaging material, various styles of

packaging are available, to suit the specific requirements.

Report on Corrugated Box Manufacturing Unit – 2002

In order to standardize the nomenclature throughout the world, an international box code

is assigned to each style. The choice of proper box style depends on the product, its

configuration and other packaging, transport and storage requirements.

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,

auto slot, carry home, and self-locking tray.

In addition to functioning as transport containers, corrugated boards are also used as inner

fitments and accessories, known in industry as inherent fitments. They anchor the

contents within the outer box to arrest transit movement. They provide cushion and

protect fragile articles during transit.

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.

8. Imperative contacts in India

The Federation of Corrugated Box Manufacturers of India

138, Mittal Industrial Estate No. 3

M. Vasanji Road, Andheri (East)

Mumbai 400 059

India

Telephone: +91-22-850 0687, 8504523

Facsimile: +91-22-850 4523

E-mail: admin@fcbm.org

Report on Corrugated Box Manufacturing Unit – 2002