Production

Raw materials:

1. Paper
2. Heat
3. Glue

1. Paper:
 10 GSM to 440 GSM
 2200 mm Max Size
 Water proof coating
 Fire Resistance ( Polycoating )
 Anti-bacterial


2. Heat: 4 metric ton boiler (Briquettes to burn)

Briquettes: Oil extracts, Agricultural waste

3. Glue: Starch (Corn/maize) + Borax + Caustic Soda(NAOH) + water

 Insects attracted to corrugated box: Silver Fish, Termite, Cockroach

Score=crease

Slit=Cutting

Objectives:
1. Reduce Wastage
2. OTIF: On Time – In Full
On Time = Delivery as per the promised date
In Full = Quantity as per the PO
3. Finishing Efficiency (machine)
4. Customer Complaints
5. Cost Saving

Target: should be 95% in total of the below requirements

 1. Wastage: 14% Target (8% in trimming & 6% in Process waste)
2. Finishing Efficiency = Target for Machine
 Corrugation: 70,000 SqMtrs Per day ( 16hrs)
 Topra: 17,000 box per shift
 Auto Gluer: 17,000 box per shift
 Jumbo: 4,000 box per day
 Auto Sticher: 4,000 box per day
 Die Cutter: 14,000 box per Shift
 Flat Bed: 15,000 box per Shift
 Pallets: 1,000 box per day

3. Customer Complaints : target – Zero

Max – 3(per month)

4. Cost Saving – As per scheduled annual target

Machine Size:
22,000 mm

Flute:
Flute Flutes per Flute thickness Flutes per Flute thickness
designation foot (in) meter (mm)

A flute 33 ± 3 3⁄16 108 ± 10 4.8

B flute 47 ± 3 1⁄8 154 ± 10 3.2

C flute 39 ± 3 5⁄32 128 ± 10 4.0

E flute 90 ± 4 1⁄16 295 ± 13 1.6

F flute 125 ± 4 1⁄32 420 ± 13 0.8

A flute = 5 mm
B flute = 3 mm
C flute = 4 mm
E flute = 2 mm
F flute = 1 mm
Max: 15mm (A*A*A)

Min: 1mm (F flute)

21 Combinations: A,B - A - A,C,E,F

GSM: 10 GSM to 440 GSM

Liner paper: 10 to 440 GSM

Fluting paper: 10 to 250(max) GSM

Range of Products:
 1mm to 5mm (Flute Size)
 10 GSM to 440 GSM
 50 mm to 4000 mm Box sizes

Draw factor:
 Flute should be lesser GSM than the Liner
 Flute length should be longer than the liner

Machine flow (Types):

1. Corrugation Cassette Tape: Single facer – A,C,E,F (Only flute)
2. Corrugation Cassette Tape: Single facer – A,B,A (Only flute)
3. Double ballecer – Board (Joining Flute)
4. Creasing/Score
5. Slitter/cut (2up, 3up)
6. Length cutter/NC (Numerical ) = Board Length cutter
7. Topra (1628)
1600mm W * 28000mm Length
Or
8. Jumbo

9. Auto Folder & Gluer (Inside & Outside)

Or
10. Double head auto sticher

11. Semi Auto Gluer & Sticher

12. Double head manual sticher (upto 13mm)
13. Table box Sticher (Semi Auto – 14mm)
14. Die punch/Flatten punch
15. Semi Auto Die Cutter
 16. Stretch Wrapping machine
17. Pallet / Legs

Stacking: Pile of something

Trim/Slotting: Cutting edges (waste)

Slit: Cutting (Dividing box 2up, 3up)

Score: Crease (Line of bend)

MOQ: Minimum Order Quantity

BOM: Bill of material

Manufacturing Joint: Place at which the board joints to frame a box by glue or stiching

CFC – Corrugated Fiberboard Conatiner

Corrugated fiberboard sometimes known as corrugated board, is a combined paper-based
material consisting of a fluted corrugated medium and one or two flat liner boards.
Corrugated boxes are used frequently as shipping containers. Boxes need to contain the
product from manufacturing through distribution to sale and sometimes end-use. Boxes
provide some measure of product protection by themselves but often require inner
components such as cushioning, bracing and blocking to help protect fragile contents.
Other important functions of a corrugated box is to provide product protection and
sufficient stacking strength during storage.

Regular Slotted Cartons (RSC)

It is the most common box style, where all of the flaps have the same length. The longer
flaps meet in the middle of the box & the smaller flaps do not meet. These boxes always
require glue or staples to close. These boxes are supplied in collapsed form (Shipped flat)
There are two ways of measuring a box a) Internal Dimension – ideal for product fitment.
b) External Dimension – for pelletizing or container load ability.
Design
Esko – Artios CAD

KLW – Key Line Drawing

Kongsberg machine

Printing:

Offset Printing: 28*40 inch (small print – Less price)

42*54 Inch (Big – Price is 5X higher)

Glossy, Matt finish etc

Digital Printing: Photo Printing Method

Flexo Printing:

Screen printing:

Testing
Lorentzen & Wettre Tester (L&W) from Swedan
• ECT – Edge Crush Test (Board)

• FCT – Flat Crush Test

• RCT – Ring Crush Test (Paper)

• BCT – Box Compression/Crush Test

• BS – Bursting Strength Test ( 60Kg)

• PS - Puncture Strength Test

• PAT - Pin Adhesion Test (Paper Joint/Bonding test)

• Compression Strength Test (5000 kg capacity)

• GSM test – Gram per SqMtr test

• Boards GSM

• Cobb Test – Water absorption test

• Viscosity& Solid Content Tester – For glue to measure

• Moisture Meter – To measure the moisture in the board

• Conditioning Chamber – To check Temperature and Humidity ( product capacity in different

regions)

• CMT – to determine FCT

• Fibre Peel off

• Delayering

• Caliper

 Dimension

 Moisture

 Printing

 Box Formation

 Defects