LIVE PROJECT REPORT

Report

ON

Corrugated packaging industry

(FULL ON MANUFACTURE PROCESS)

Submitted in partial fulfillment of the requirement for the degree of the bachelor of business
administration of the medi-caps university, indore

(batch2016-2019)

B.B.A. 3rd semester 2nd year

Submitted To: Submitted By:

Preeti Vishnu sahu

Amber soni

Ajay solanki
 candidate declaration

I, VISHNU SAHU , ROLL NO. MS16MS301059 OF MEDICAPS UNIIVERSITY studying in b.b.a. here
I declared that I and my team we have successfully completed my our live project from the
capital builder on corrugated kraft paper box (full of manufacture process) during the
Academic year 2016-2017. The information is submitted is true and original to best of my
knowledge.

DATE:

PLACE: INDORE VISHNU SAHU

 PREFACE

The successful completion of this project was a unique experience for me as I got an
opportunity to visit many place and also interact with various people, I achieved a better
knowledge about the manufacture and inventory planning. Which I gained by doing this project
was essential at this turning point of my career. This report is being submitted, whose detailed
analysis of the research is undertaking by me .

This report title the study of material management is an attempted to allow the reader to
understand the how company set up their manufactory plan or inventory control to achive their
organizational objective.
 ACKNOWLEDGEMEN

Dissertation Report is a bridge connecting the educational and professional use. It is the path
leading to success by shouldering responsibilities under the careful guidance of seniors and
experienced personnel without fear and failures.

.It gives me immense pleasure to take the opportunity to remember and thanks to the
personalities who are involved with this project work during its study stage during my days of
hard work. I feel that it is my duty to express thanks and deep gratitude to everyone who is
directly or indirectly associated in the completion of this Dissertation Report.

With deep reverence, I offer my deepest regards gratitude to who is my group

members and , my teacher preeti , without whom this Report could not
have been fulfilled.

Medicaps university
 Product description

Introduction

Corrugated kraft paper board box, technically called corrugated fiber board box
is the most popular shipping container, now a days. The box is manufactured from corrugated
board which consist of 3or more layer of kraft paper. The boxes find their number of
application in the packing of chemicals & drugs, tobacco, engineering good, canned & bottled
goods, food product, lamp, electrical appliances, glassware ect.

Packing play a very important role in the country economy. Till recently only the western
world, more particularly the developed country cared about proper packing. However now
even developing country like india have changed their outlook towards packing and in the last
few year increasing stress has been laid on improved and proper packing. In fact, today, packing
is an important as an content.

Corrugated boards were first produced india in early fifties. Since then the production of
corrugated boards has increased steadily. Corrugated box has replaced wooden boxes and
crates in many application. Today about 80% of all shipments in the world are being made in
fiber board boxes. In india about 60% of the packing is being done with corrugated fiber board
boxes.

Corrugated fiber board consist of a flat layer of a paper sheet glues on one or more side of a
corrugated board is made by passing two layer of paper corrugating machine. one layer of
paper become corrugated after being passed through the heated roll and other is brought into
contact with it after former having glued at tips.
ADVANTAGES OF CORRUGATED FIBER BOX-

Corrugated box have replaced the wooden and tin container due to the several
advantage for safe transportation of the good. These are discussed at here under:

Light in wait.(freight advantages)

Cellular structure with high compressive strength, resiliency &shock resistance.
Can be stored conveniently in folded condition when not in use those saving storage
space.
Can be attractively printed thus advertisement.
Easy to fabricate.
Contents packed in this boxes remain dust free.
Available throughout the year.
Re-usable.
No strapping necessary.
Desired in export market.
Expedites production due to one line conveyor packing.
Eliminate dependency on natural wood.
By lining lamination or coating they can be made water resistant and resistant to other
adverse condition.
Some of the product where corrugated fiber board boxes find extensive application are:-

1. Pharmaceutical.
2. Glassware, crockery ware.
3. Soaps and cosmetics.
4. Electronic product.
5. Foot wear.
6. Milk product and food product.
7. Automobile component.
8. Tea and coffee.
9. Cashew nut industry.
10. Frozen fish.

It would not be an exaggeration if one stats that practically

every product at some or other stage,has to packed in corrugated paper or box. At the
manufacture or wholesaler level the individual unit of a particular item or packed together in a
cartoon box for the sake of convenience in handling/ transporting.

The strength or weakness of corrugated box depend on the member of ply, which vary from 2
ply to 9 ply. The higher the number of the ply the thicker and the strong will be board.for
example to pack vials and tube.
 Market potential

Paper and board industry has grown over the year to meet the ever increasing need for paper
as well as paper board. This industry is more than a century old.

Specific statistics are not available in respect of the production in the small
scale. However an important parameter for gauging the market potential for the product
envisaged in this scheme is to ascertain the overall growth in the industry in general particular
reference to the growth of users industries that require corrugated box.

A look at the user industries indicate that they have generally grown over
the year and as per the indication will continue to growth in the coming year as well.

Consequently the demand for corrugated paper board will also continue to be buoyant. A
particular 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 order and are working to capacity.

An important factor for successful undertaking of corrugated paper box is the capacity to
produce order from bulk users on contracts basis. Only large and regular order will endure
stability to the unit.

Through the market potential for these product can be consider to the fairly good, much will
depend upon the marketing strategy adopted by an individual entrepreneur.
 PROCESS FLOW CHART

Corrugated sheet corrugating plant

Printing

Printed paper sheeet

cutting board cutter

glueing sheet pasting machine

3 ply board

Cutting cutting & creasing machine

Slotting slotter

Stitching stitching machine

Finishing prduct
RAW MATERIAL:-
Fast growing pine trees provide the primary raw material used to make corrugated cardboard.
The largest packing company on thousand of acres of land where trees are matured harvested
and replaced seedlings. After the trees are harvested they are stripped of their limbs only the
trunk will be shipped by the truck to a pulp mill. The largest packing company also own the mill
where trees are converted to the kraft paper. At the mill the harvest tree trunk are subjected to
the kraft process also known as the sulfate process because of the used of chemical to break
down the chips into fibrous pulp. After pulping and other processing the fibers are sent directly
to the paper machine where they are formed pressed dried and roll into the wide heavy roll of
kraft paper sent to the corrugating plant to be made into cardboard.

At the corrugating plant only the few other raw material needed to make a finished box. Corn
starch glue used to bond the corrugated medium to the linear sheet. Because so much glue is
used rail cars tanker deliver it as a dry powder that will be used in huge silos at the corrugating
plant until it is needed. Drawn from the silo, the dry corn starch is mixed with water and other
chemicals and pumped into the corrugator to be spread on the corrugated medium as the
layers of liner are added. Other raw materials are used to finish the corrugated cardboard after
production. Waxes made from paraffin or vegetable oils can be applied to make a water- or
grease-resistant container for food products. Brightly colored inks are also applied to create
bold graphic designs for self-supporting displays featuring product name, information, and
company name and logo. Teams of salespeople and designers work together to create the
manufacturing and printing patterns, called dies, that are used to cut and print a specific box
design. The dies are created in a pattern shop and transferred to the rotary die-cutting
equipment and printers that finish the box blanks.

Design
Kraft paper has been manufactured since 1906. Since then, pulp processing, paper making, and
corrugating operations have been developed to a high state of efficiency and productivity.
Today, in the corrugated cardboard industry, designers are creating innovative containers that
require four-color printing and complex die-cutting. These innovative containers are designed
with sophisticated software such as computer-aided design (CAD) programs, allowing a
packaging designer to brainstorm different package designs before manufacturing begins. A
designer using a CAD program can call up and modify different designs that have been stored in
a computer design library. Thus, existing packages can generate new designs. Many retail stores
use such light, strong, and colorful containers directly, as point-of-purchase displays.
The Manufacturing
Process

Pulping the pine chips

1 Manufacturing a corrugated cardboard box begins with the pulping of wood chips in
the kraft (sulfate) process. First, tree trunks are stripped of bark and torn into small
chips. Next, these chips are placed in a large, high-pressure tank called a batch digester,
where they are cooked in a solution, or liquor, made of sodium hydroxide (NaOH) and
several other ionic compounds such as sulfates, sulfides, and sulfites. These
strongly alkaline chemicals dissolve the lignin, the glue-like substance that holds the
individual wood fibers together in a tree trunk.
2 When the pressure is released after several hours, the wood chips explode like
popcorn into fluffy masses of fiber.

Making kraft paper

3 After additional cleaning and refining steps, a consistent slurry of wood pulp is
pumped to the paper-making machine, also known as a Fourdrinier machine. Gigantic,
square structures up to 600 feet long (182.88 meters), these machines contain a wire
mesh in which the paper is initially formed. Next, the paper is fed into massive, steam-
heated rollers and wide felt blankets that remove the water. At the end, the finished
medium, or liner, is rolled for shipment.

Shipping and storing the kraft paper

4 Rolls of kraft paper for corrugating are available in many sizes to fit the production
equipment at different corrugating plants. The most common roll sizes are 67 inches
(170.18 centimeters) wide and 87 inches (220.98 centimeters) wide. An 87-inch roll of
heavier paper can weigh up to 6,000 pounds (2,724 kilograms). As many as 22 rolls of
87-inch paper can be loaded into one railroad boxcar for shipment to a corrugating
plant.
5 At the plant, the kraft paper is separated into different grades, which will be used for
the medium and the liner. These different grades of corrugated cardboard can be made
by combining different grades of kraft paper. A knowledgeable packaging specialist
works with a customer to determine the strength required for the corrugated cardboard
container being planned. Then, when a plant receives an order for containers, a product
engineer specifies the combination of medium and liner to produce a cardboard to
match the customer's requirement.
Corrugating the cardboard

6 Using powerful fork-lifts, skilled equipment operators select, move, and load rolls of
kraft paper at one end of the corrugator.

Corrugated cardboard manufacture includes two key steps: making kraft paper and
corrugating the cardboard. Kraft paper involves pulping wood chips and then feeding
the resulting paper substance through massive steam rollers that remove the water.
Corrugating is also done in a machine that utilizes heavy rollers. One roll of
cardboard is corrugated and then glued between two other layers (liners) by the
same machine. The glue is then cured by passing the cardboard over heated rolls.

7 One roll of medium is loaded to run through the corrugating rolls, and a roll of liner is
fed into the corrugator to be joined with the corrugated medium. Liner from another
roll travels up over the corrugating rolls along a flat structure called the bridge. This liner
will be glued to the corrugated medium later in the process.
8 For a large production run, additional rolls are loaded into automatic splicers.
Sensitive detectors check the rolls of paper feeding into the corrugator. When a roll is
nearly empty, the corrugator control system starts a splicer, and paper from the new roll
is joined to the end of the paper going through the machine. Thus, production of
corrugated cardboard is continuous, and no production speed is lost.
 9 The medium to be corrugated is fed into the giant, electrically driven rollers of the
corrugator, first through the preheating rollers and then into the corrugating rolls.
Steam at 175 to 180 pounds of pressure per square inch (psi) is forced through both sets
of rollers, and, as the paper passes through them, temperatures reach 350 to 365
degrees Fahrenheit (177 to 185 degrees Celsius).
10 The corrugating rolls are covered with I O flutes horizontal, parallel ridges like the
teeth of massively wide gears. When the hot paper passes between the corrugating
rolls, the flutes trap and bend it, forming the middle part of a sheet of corrugated
cardboard. Each corrugating machine has interchangeable corrugating rolls featuring
different flute sizes. Installing a different

A finished piece of corrugated cardboard consists of a single corrugated layer

sandwiched between two liner layers.

flute size in the corrugator changes the width of the corrugated medium.

11 The medium travels next to a set of rollers called the single-facer glue station. Here,
one layer of liner is glued to the medium. Starch glue is carefully applied to the
corrugated edges of the medium, and the first layer of liner is added. From the single-
facer, the medium and liner go to the double-backer glue station where the other layer
of liner from the bridge is added following the same procedure. Continuing through the
corrugator, the cardboard passes over steam-heated plates that cure the glue.
Forming the blanks into boxes

12 At the end of corrugator, a slitter-scorer trims the cardboard and cuts it into large
sheets called box blanks. Box blanks pop out of the slitter-scorer like wide slices of toast
and slide into an automatic stacker that loads them onto a large, rolling platform. From
here, they will be transported to the other machines that will convert them into finished
containers. Skilled production workers use a computer terminal and printer to prepare a
job ticket for each stack of box blanks produced by the corrugator. With the job ticket,
workers can route the stack to the right fabrication machines, called flexos (the name is
short for flexographic machine). A flexo is a wide, flat machine that processes box
blanks.
13 Printing dies and die-cutting patterns I 3 are prepared in a pattern shop on large,
flexible sheets of rubber or tin. The dies and patterns are loaded onto the large rollers in
the flexo, and the box blanks are automatically fed through it. As each blank passes
through the rollers of the flexo, it is trimmed, printed, cut, scored, and, in a printer-
folder-gluer, folded and glued to form a box. From the flexo, the finished boxes are
automatically stacked and sent to a banding machine to be wrapped for shipping. Other
equipment in a corrugating plant includes stand-alone die-cutters, die-cutters with print
stations, and machines known as curtain coaters that apply a wax coating to fruit,
vegetable, and meat containers. Box blanks requiring only simple, one-color printing and
die-cutting can be run through a stand-alone die-cutter, print station, and curtain coater
to produce water- or grease-resistant containers.
APPENDICES (ADDRESSES)
 APPENDIX- 1

SOURCE OF PLANT &MACHINERY AVAILABILITY

CORRUGATED KRAFT MAKING MACHINE:-

NATRAJ INDUSTRIES
PLOT NO.65, SECTORE-6
FARIDABAD(Haryana)-121006
Tel: 0129-2241403/404,4001259
fax: 0129-2214103
Email:sales@natrajindustries.com
Website:www.natrajindustries.com

Sidhartha machinery co.

406, usha kiran building
commercial complex
Azadpur, dehli-110033
Tel: 65976383
cell: 9811755369
Email: sales@sidharthamachinary.com
Website:www.sidharthamachinary.com

Paper board machinery company,

B.kumar compound,
lalbahadur shastri marg,vikhroli
Mumbai-400083

Printpackengineers
20, gujrat bhihar
vikas marge,
new dehli-110002
 APPENDIX-2

SOURCES OF RAW MATERIAL AVIALABILITY

Kraft paper:-

Coastal paper ltd.

Industrial development area
Madhavreyudupalem-533126
Near kadiam (R.S.)
East Godavari distt.
Andhara Pradesh
Tel: 5348,5423

Associated plup & paper mills Ltd.

B jadav chambers,
2nd floor, ashram road,
Ahemdabad-380009.

Ballapur industries ltd.

(Shri gopal division)
Thapar hous,
124, janpath,
new dehli.

GUM TAPE

Million tape manufacturing co..,

2640, Himlton road,
Kashmere Gate,
Dehli-110006

Natraj paper industries,

38/46, Nagdevi street,
Mumbai-400003.
 GUM:-

Vijay adhesives industries,

6,friends colony,
G.T. road, shahdara,
Dehli- 110032.

Corn product co. (india) pvt.ltd,

Shree nivas house,
Hazarimal somari marge,
P.O. Box no. 994,
Mumbai.

Stitching wire:

Pearls products,
Amar hill,
Saki vihar road,
Powai, Mumbai.

Universal wire manufacture co.

61/63, jalan wadai,
Gokhle road, dadar,
Mumbai.

Saif steel trader,

Steel house,
10/14, janjikar street,
Mumbai-3.
 Printing ink:-

Graphichem sales,
Bhupender bhawan,
Karishma market, paharganj,
New dheli-110055.

Coats of india limited,

Transpot depot road,
Kolkata-700088.

Bengal chemicals (p) ltd,

25, brabourne road,
Kolkata-700001.

Colour Inks (p) ltd,

136, laxmi building,
A-mudaliar road,
Bangalore-2
 APPENDIX -3

EXISTING MANUFACTURES

There are numerous units engaged in the manufacture of corrugated kraft box all over the
country some of them area mention below:-

Grover packaging industries

Rz-44B/6,Tughlakabad EXtn.
New dehli-110019
Tel: 55732877
Fax: 26069416

Kwality packging products

Bisokhar road
Modi nagar- (u.p.)201201
Tel: 02132-233028

Suraj packging company

39-channamal park
Rohtak road
New delhi-110026
tel: 28314650, 28312752
CORRUGATED RECYCLING PROCESS
 Recycling process

Corrugated is a highly useful, cost-efficient, versatile packaging material that is used to

ship just about every product under the sun, all around the world. But it doesn't stop
there: corrugated is also the most-recycled packaging material on earth, with a recovery
rate of about 73 percent. Businesses, retailers and consumers at home collect and
return their used corrugated containers to be recycled into new ones. While almost
everyone contributes to corrugated's recycling success, fewer people may know where
those boxes go from the collection point, or how they are processed to produce new
corrugated material.

Here's how corrugated is recycled:

1. Clean, old corrugated containers (OCC) are collected, in many instances as part of a
mixed recyclables stream. To optimize recyclability, containers should be free of
contaminants such as food, metal foil, wax, etc
. 2. The collected OCC is sorted, compacted and baled for space-efficient storage and
handling, either at the point of end-use (store or business) or at the recycling center.
3. Bales are transported to the paper mill.
4. Bales are broken open, and OCC is put into a repulper (a huge tub that looks
something like a blender) with water. It is agitated to form a slushy pulp (slurry) of fiber
and water.
5. a. A big "ragger" chain or rope hangs down into the swirling tub of material. Some
contaminants such as long pieces of rope, string
b. The remaining pulp slurry goes through different types of equipment such as towers
where the metal falls to the bottom for removal, screens, cyclones, and even big tanks
where the contaminants float to the top and can be scraped off. The cleaned pulp is
then sent to the paper machine.
6. The highly diluted fiber solution is poured out onto a moving screen which allows
water to drain away, forming a continuous fiber mat, which is pressed between rollers
to remove more water.
7. The wet, continuous fiber web is then wound through the dryer section where the
top and bottom of the web allternately contact the heated surfaces of the drying
cylinders, removing the remaining moisture from the paper.
8. At the end of the paper machine, paper is rolled up on a large reel spool which can
weigh 10-60 tons.
 9. The reel is then slit and rewound into individual rolls. The recycling process is
complete; the new paper rolls are shipped to box manufacturers to begin the next stage
in life to become new corrugated boxes.
 Future trend
Increasing demand and high volumes will trigger consolidation and setting up of large
automatic plants.

Inline Automatic Board and Box making plants will ease out the present semi automatic
production processes.

Deployment of Folder Gluers, Rotary Diecutters will be on the increase.

Use of corrugated for display/promotional packs, POPs and dispensers.

Advances in multicolour, flexo printing will facilitate in-house flexo printing and do away with
screen printing, contract printing on offset presses.

The emergence of e-commerce, reverse bidding, concept of First Pak will give large scale
units the advantage of competitiveness and the concept of locating corrugated box units nearer
to user locations will become obsolete.

Large Corporates and Bulk users of corrugated boxes looking for single/multiple alternative
vendors capable of meeting stringent specifications, offering alternative designs, test-in-time
deliveries at optimum cost.

Growing interest in machines made in China, Taiwan and other Asian countries. 55
MACHINES

GK-1080T Window Patching Machine is widely used in the film patching to be package with or
without the window of the wine box .gift box.napkin box.cosmetic box etc.It can also realize the
function of the paper gluing ,film patching ,film cutting and paper collection before folding
boxes. The machine has passed the ISO9001 Quality System Certificate and conform the
European CE safety standard.

Series A Model A 2-fold folding gluing machine, adopt synchronous belt transmission and
electronic continuously variable speeder, domestic standard electronic componentsfeeding
section adopt mechanic continuously variable, stable and easy to control and operate. It is
widely used in food, medicine, cosmetics, stationery and other ordinary cartons, perfectly
combing the requirements of auto packaging together. (in case of any special function required,
we can design according to the customers requirement.
Company profile:-

Established in the year 1991, Sureka Paper Containers Private

Limited is one of the distinguished business names highly immersed in manufacturing, trading

and supplying a comprehensive spectrum of Corrugated Boxes, Corrugated Roll, Corrugated

Sheets. These are designed and developed beneath the supervision of dexterous executives by

making use of top grade material along with modern machinery. Widely cherished for their

reasonable pricing structure, these offered products are highly recommended. Also, we offer

customization facility makes us a popular market choice.

Our company has attained a notable place in this industry by presenting to our customers an

exceptional quality range of products. We have hired our employees after analyzing them on

several measures such as industry experience, knowledge and qualification. As well, we

organize several training sessions periodically so as to keep them rationalized with the modern

alterations of rules and regulations in this realm. In order to meet numerous necessities of our

clients, these personnel invest all their skills and sound business knowledge in providing altered

solutions to them.

Under the able patronage of our mentor Sanjeev Sureka, we have attained tremendous success

and reputation in this competitive business industry. His quick decision-making capabilities and

exceptional business skills have always assisted us in becoming one of the preferred business

names.
Basic Information

Nature of Business Manufacturer

Additional Business Supplier

Company CEO Sanjeev Sureka

Total Number of Employees 26 to 50 People

Year of Establishment 1991

Legal Status of Firm Private Limited Company

Statutory Profile

Banker BANK OF INDIA

Pan No. AAFCS*****

Tan No. BPLS0*****

 Value Added Tax Registration No. 23861200304

Service Tax Registration No. AAFCS7021MST001

Excise Registration No. AAFCS7021MXM001

GST No. 23AAFCS7021M1ZB

Packaging/Payment and Shipment Details

Cash
Credit Card
Bank Transfer

Payment Mode Cheque

DD
Online

Shipment Mode By Road

WHY US

Modernization is our specialty and we are highly instrumental in presenting incomparable

quality products to our patrons. Preserving all the quality limitations, a crew of personnel

develops these products in tandem to the guidelines laid in the business. Following are the for

success:

Timely delivery

Quality assured range

Ethical business practices

Clarity in business operations

Flexible payment modes

Reasonable rates
CLIENT SATISFACTION

Since our inception, we have been working as a leading company engrossed in presenting top

class products to our customers. For the convenience of our clients, we provide our products in

a range of stipulations so as to cater their specific demands. Presented products are provided

by skilled personnel in tune with the quality guidelines. The presented product is highly valued

in the market for their long lasting finish. Also, our products could be modified to meet with the

ever rising needs of our customers in order to attain the trust of our clients.
 CORRUGATED BOXES AND SHEETS

Corrugated Boxes
Leading Manufacturer of Carton Packaging Box, Heavy Duty Corrugated Boxes, Regular
Corrugated Boxes, Corrugated Boxes, Printed Corrugated Boxes and Industrial Corrugated Box
from Indore....more

Carton Packaging Box

Heavy Duty Corrugated Boxes
Regular Corrugated Boxes
Corrugated Boxes

Corrugated Roll
We are a leading Manufacturer of Customized Corrugated Roll, Paper Corrugated Roll and
Corrugated Roll from Indore, India....more

Customized Corrugated Roll

Paper Corrugated Roll
 Corrugated Roll

Corrugated Sheets
Providing you the best range of Corrugated Sheets with effective & timely delivery.

Corrugated Sheets
Print Corrugated Box

Juice Corrugated Box

Cake Corrugated Box

plain corrugated box

Red Print Corrugated Box

Corrugated For Candy

Fruit Corrugated Boxes

Cartoon Box

Telescoping Container
Factory visit