Project Report

Of
Corrugated Box Manufacturing Plant
 INDEX

S.NO TITLE PAGE NO

1 INTRODUCTION 4

2 MARKET SURVEY & FUTURE SCOPE 8

3 COMMERCIAL DETAILS 10

4 THE PRODUCT AND SERVICES 12

5 MARKET POTENTIAL 14

6 LOCATION OF THE UNIT 17

7 THE TECHNOLOGY 17

8 MANUFACTURING PROCESS 18

9 PROCESS FLOW CHART 20

10 QUALITY ASSURANCE &SPECIFICATIONS 21

11 PLANT & MACHINERY 23

12 SCHEDULE OF IMPLEMENTATION 29

13 GOVERNMENT SCHEMES 30

14 FINANCIAL ASPECTS 33

15 A. FIXED CAPITAL

16 1. LAND AND BUILDING 33

17 2. MACHINERY AND EQUIPMENT 33

18 3. ELECTRICAL INSTALLATION, ERECTION & 34

COMMISSIONING

19 4. OTHER FIXED ASSETS 34

20 5. DETAILS OF OTHER DEPOSITS 35

21 6. PRELIMINARY & PREOPERATIVE EXPENSES 35

22 B. ECONOMICS OF WORKING

23 1. RAW MATERIALS & CONSUMABLES 35

24 2. MAN POWER/EMPLOYMENT DETAILS 36

25 3. ELECTRICITY LOAD 36

26 4. OTHER CONTINGENCIES 36

27 5. WORKING CAPITAL ESTIMATES 37

28 C. MEANS OF FINANCE 37

29 D. SOURCE OF FINANCE 37

30 E. BASIS & PRESUMPTIONS 38

31 FINANCIAL ANALYSIS

32 A. ESTIMATED COST OF PRODUCTION & PROFITABILITY 39

33 B. CASH FLOW STATEMENT 40

34 C. DEBT SERVICE COVERAGE RATIO (DSCR) 41

35 D. PROJECTED BALANCE SHEET 42

36 E. RETURN ON INVESTMENT (ROI) 43

37 F. BREAK EVEN POINT (BEP) 43

38 CONCLUSIONS 44
 Table of Content Page Nos.

MSME Registration No
And Registration Date

Index

Introduction and Market Survey

Future Scope

About the Product

Manufacturing Process

Investment Cost

Licenses

Marketing Strategy

Target Customers

The corrugated box Industry is an inevitable part of

manufacturing sectors which rely heavily on corrugated
packaging for finished goods transportation and handling.
Asia pacific enjoys the leading position in the global
corrugated boxes industry on account of a large consumer
base and rapid economic development in countries such
as china and India. The global corrugated boxes market
reached a value of US $184.6 Billion in 2019, registering a
CAGR of 4.6% during 2012-2019. Whereas Indian corrugated
box industry grew at a CAGR of 23.3% in terms of revenue.

Corrugated board boxes are used in different area of packing in

goods such as breweries, glass wares, cigarettes,
Pharmaceuticals, Biscuits, Milk & Milk products, soap,
Cosmetics, Tea & Coffee, Hosiery, Shoe & Footwear industry,
toys etc. So likewise the market size of corrugated boxes in
India is very big and has a great growth potential especially
after the ban of plastic packaging. This has poised to drive the
demand of corrugated Board packaging. Factors such as
increasing demand from fresh food and beverages, home &
personal care goods, electronic goods industries, logistics
application, increasing consumer awareness towards
sustainable packaging and growth of the e-commerce industry
have propelled the growth of Indian corrugated boxes market
and it is expected to grow more in the future.

Also, India is a country where the labour is very cheap and

technology wise it has great future. Therefore India is a perfect
destination for making corrugated boxes. It can be reused,
reshaped, foldable, light-weight, cost-effective, comes in various
shapes and sizes & it is truly eco-friendly. Thus all these factors
add economic value to corrugated box manufacturing units.

The corrugated boxes market is growing rapidly and faster

than expected, with the help of the explosion of e-commerce,
instalment of high speed automatic machines, developments in
digital printing technologies and with many more factors.

The Indian Corrugated Box manufacturing industry is presently

worth INR 15,000 crore. The growing Indian middle class and
changing lifestyles have witnessed the corrugated box industry
increasing by 12-14% annually in the past five years. India
corrugated box market is expected to register positive CAGR of
around 21.8% and to reach over INR 63,000 crore by FY’2023.

Hence there is no match or perfect substitute to this product

and it’s a piece of wonder at unimaginably cheap amount. It is
going to occupy more space in the coming times.
FUTURE PROSPECTIVE OF THE INDUSTRY

Some of the factors which will change the future of Corrugated boxes market –

 Explosion of E-commerce –
E-commerce retail sales are continuing to rise higher and further it is expected to grow
more. Global online sales are supposed to be over $5.5 trillion in 2023. This will have a
huge impact on packaging demand, particularly in the corrugated industry as it
represents about 80% of demand in the e-commerce market.

 Digital Printing Growth –

Brand owners are identifying the opportunities to grow falling brand loyalty through
greater engagement with their customer base provided by these technological
improvements and they consider packaging as an essential component in the creation
of a memorable shopping experience for the users that will also help them to attract
new buyers.
So, Digital Printing techniques for corrugated boxes play a vital role here.

 Sustainability –
Corrugated board is becoming popular in packaging as sustainability becomes a more
critical issue across the industry.
These boxes are simpler to recycle and the pulp and paper industry is already good at
converting these into new generations of containerboard.
Light-weighting of these boxes has long been impacting the corrugated industry.
Right weighting and right-sizing are playing an ever-rising important role in this
market.
The importance of light-weighting will continue to be dominant over the coming years
as retailers look to save costs as well as appealing to end-users.

To meet the growing demand for international quality packaging, corrugated packaging
manufacturers in India are speedily moving on the path of modernization.

Corrugated packaging manufacturers in India are ready and eager to embrace new
technologies that can help them to meet the demands of their customers for international
quality boxes. And Also,

 Increasing demand from fresh food and beverages, home & personal care
goods, electronic goods industries will increase the reach of end users towards
corrugated box manufacturers.
 Increasing the demand of safe and cushioned packaging of the product will
augment the growth of India Corrugated box market.
 Rise in procurement of latest technology machines from China, Taiwan and other
Asian countries by manufacturers in order to make production fast and accurate will also
 drive the future of India corrugated box industry.

All of these are expected to have positive impact on the overall revenue of corrugated box
market.

CAPITAL EXPENDITURE

SR. No Description Size Price (INR)

Heavy duty high speed oblique type Single
1 facer paper corrugating machine Complete 52" 9,95,000
with Reel Stand Self-loading Hydraulic - Finger
Type
2 Sheet Cutter Gear Model 52" 2,70,000
3 Sheet Pasting Machine 85" 1,55,000
4 4 Bar Rotary Creasing and Cutting Machine 85" 3,75,000
5 Eccentric Slotter 85" 3,80,000
6 Box Stitching Machine 42" 72,000
7 2 Colour Flexo Printer 52 X 72 6,80,000
Total Machinery Cost 29,27,000
1 Executive Office Table with Chairs ₹ 1,20,000
2 Tables (5*2 Feet) ₹ 49,000
3 Chairs (Non-rotatable) ₹ 21,000
4 Lights (LED High Bay Lights) ₹ 76,000
5 Fans ₹ 22,083
6 Industrial Roof Ventilators ₹ 6,798
7 Fire Extinguisher ₹ 16,000
8 Computer ₹ 15,000
9 Refrigerator ₹ 15,759
10 Microwave ₹ 6,200
11 Cupboard ₹ 17,000
12 Split AC ₹ 1,04,997
13 Sofa (3 Seater) ₹ 14,000
Total Fixtures & Furniture Cost 4,83,837
WORKING CAPITAL ESTIMATION

Labour Cost (Per Day) No. of Cost per Total Cost

Workers Person
Unskilled 347 6 1,04,100 6,24,600
Semi-Skilled 382 4 1,14,600 4,58,400
Skilled 442 2 1,32,000 2,65,200
Accountant-cum- 401 1 1,20,300 1,20,300
typists
Peon 332 1 99,600 99,600
Security Guard 421 1 1,26,300 1,26,300
Total Labour Cost 16,94,400
Raw Material Cost Per Box No. of Boxes made in a Month Total Cost
Kraft Paper 18 50,000 90,000
Adhesives 0.6 50,000 1,40,000
Stitching Wire 0.5 50,000 2,90,000
Total Raw Material Cost 12,70,000
Rent Per Month Total Cost
Udyog Vihar, Industrial Area 60,000 7,20,000
Total Working Capital Required 28,65,600

Additional Information
Working Hours per Day 8 Hours
No. of Working Days in a week 6 Days
Total no. of Working Days in a year (After 300 Days
deducting all the Holidays)

LICENCES REQUIRED

Every business has a legal requirement and thus every business needs a proper legal
environment and for this every business needs some specific kind of licences to operate
smoothly and run it. These licences are –

1) Company Registration Certificate – every firm which is a company has to register

with the Registrar of Certificate (ROC) then only it will come into existence and can start
its operations.

2) Trade License – It is a certificate that allows a company to carry on the business or trade
 activities with in a particular area or municipal limit. This license is issued by the local
authorities (Municipal Corporation) to the traders and establishments to controlling or
monitoring the business and trading activities within the city.

3) GST Registration – businesses whose turnover exceeds Rs. 40 lakhs* (Rs 10 lakhs for
NE and hill states) is required to register as a normal taxable person. This process of
registration is called GST registration. For some businesses, registration under GST is
mandatory.

4) Pollution certificate – The Ministry of Environment, Forest and Climate in India works
for checking the air, water, and noise pollution by ensuring the quality is maintained. It
also issues guidelines for the purpose. Additionally, every state has its own Pollution
Control Boards.

5) MSME/SSI Registration – Every business registered in India is provided certain

benefits by the government of India based on its classification in the type of entity it is
i.e. Small, Medium or Micro. When you register a Micro, Small and Medium
Enterprise, you will get an MSME certificate (provisional or permanent).
This MSME certificate helps you enjoy various benefits like priority sector lending
(you get loans easily), differential rates of interest (you pay lesser interest on
loans), various exemption under tax laws, get environmental clearances, etc.

6) FEFCO GMP Certificate – GMP means having a total control system in place in each
manufacturing plant. The purpose is to ensure that from the purchase of raw material to
the delivery of the finished product to the customers' premises, all parameters of quality,
hygiene and traceability are monitored.

7) Licence as per Bureau of Standards

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
refrigerators, TVs, Air Coolers, fans etc.
16. Stationary items
17. Match boxes
18. Frozen fish
19. Apple, cherry, grapes etc.
20. Cashew nut industry
MICRO, SMALL & MEDIUM ENTERPRISES
Manufacturing Enterprises –The enterprises engaged in the manufacture or production of goods pertaining to any
industry specified in the first schedule to the industries (Development and regulation) Act, 1951) or employing plant
and machinery in the process of value addition to the final product having a distinct name or character or use. The
Manufacturing Enterprises are defined in terms of investment in Plant & Machinery.
TARGET CUSTOMERS

As we got to know earlier that corrugated boxes are widely used in

almost all the industry for safe transportation but for this project we
will be concentrating on just 6 products.
These products or rather industries are –

1) E-Commerce
2) Electrical Appliances
3) Chemicals & Drugs
4) Food Products like Chips
5) Stationery Items
6) Textiles

Introduction:

Packaging plays an important role in allowing products to respond to the

demands and needs of modern consumers. Packaging is one of the most cost-

effective weapons in a marketer’s arsenal. It requires a relatively self-effacing

investment, lasts a long time. The role of packaging in business has

undergone a major change, and it has today assumed a very major role.

Traditionally, packaging was defined as the activities of designing and

producing the wrapper or container for a product. This definition is no longer

adequate. Today, packaging has emerged as a major technology in itself,

which is highly complex and specialized, highly multi-functional, cross

functional and very application oriented. Corrugated paper board boxes are

one of the safest and efficient means of packaging and shipment of goods.

Corrugated board consists of a flat layer of paper sheet (liner) glued on one

or both sides of a corrugated paper. The corrugated board is made by passing

 two layers of Kraft paper through corrugating machine. One layer of paper

becomes corrugated after being passed through the heated rolls and other is

brought into contact with it after the former having glued at tips. 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”. Similarly, board can be pasted to form thicker boards i.e. 5-ply, 7-ply

and 9-ply etc.

The Products & Services:

The unit/firm is focused on manufacturing corrugated kraft paper board and

boxes, which are an essential material in packing of a product. The products

are used for packaging and shipment of FMCG, electronics, pharma, medical,

textile, garments and other related products. The targeted customers belong

to the following sectors:

 Food & beverage

 Electronic goods

 Home & personal care goods

 Chemicals

 Textile goods

 Paper products
  Others (Pharmaceuticals, rubber, and tobacco)

Sector-wise distribution of corrugated packaging in India

1. RAW MATERIAL REQUIREMENTS

 Craft Papers
 Glue
 Staples wire etc.
 Packaging Material

2. MANUFACTURING PROCESS

Calculation has been based on single corrugated sheet pasted with one sheet of craft paper.
Two paper reels are run together on corrugated machine. One layer of paper becomes
corrugated after passing through the heated fluted rolls and other is brought in contact
with the former having been glued at the tips. These two get pasted together and are
wound in rolls. These will be procured on job work. By cutting this roll with board cutters
and gluing the corrugated side on pasting machine. A double face board is produced by the
3rd ply of paper over it. This board is kept under a sheet pressing machines for some time
for setting of wet glued sheets. Similarly board to board can be pasted to form thicker
board i.e. 5 Ply, 7 Ply and 9 Ply etc.
1. INTRODUCTION
Corrugated cardboard is generally used to make packing or shipping containers. Though
there are various other types of cardboard boxes available, corrugated cardboard boxes are
the most suitable for maintaining the safety of the object it is carrying, especially for long
distance shipping purposes. This is because they are made of corrugated paper,
manufactured from fiber and is sandwiched by cardboard. This setup makes it very sturdy
and ensures the delivery of the articles that it is carrying with zero damage. While some
corrugated boxes are made out of plastic, the majority is limited to paper. Corrugated boxes
confirm safety and protection of the product being shipped. It also offers durability, cost
effectiveness, lightness, strength and recyclability which make it an ideal choice for
merchandising and marketing of goods with ease. They are also known to have a good
stacking strength. Stacking strength refers to the pressure that is formed during stacking.
This is a great advantage for transportation. The stacking strength of the corrugated box
also plays a vital role in providing crush resistance and product protection.

MARKET POTENTIAL AND MARKETING ISSUES, IF ANY

With the steady rise in the industrial production, the demand for corrugated paper boxes
increasing every year. These boxes have got distinct advantages such as light in weight,
easy to fabricate as per required specifications. The corrugated papers and boards may also
find market in the rural areas for packing of fruits, vegetables & eggs.

Corrugated is made of paper and has an arched layer, called "fluting," between smooth
sheets, called "liner." This arched layer provides corrugated with a very high strength‐to‐
weight ratio.
2
 The corrugated most commonly used to make boxes has one layer of fluting between two
smooth sheets. But there are many types of corrugated available, each with different flute
sizes and thicknesses.

Corrugated Paper boxes are extensively used in the packaging of industrial as well as consumer goods. In some of
products like crockery, electronic items, automobile components, glass and cigarettes, pharmaceuticals, soaps &
cosmetics, biscuits, hosiery, toys, rubber & rubber products, refrigerator, cooler & fans, proper type of packaging
becomes very important

DETAILED PROJECT REPORT

DETAILED PROJECT REPORT

Introduction: Packaging plays an important role in allowing products to respond to the demands and needs of
modern consumers. Packaging is one of the most cost-effective weapons in a marketer’s arsenal. It requires a
relatively self-effacing investment, lasts a long time. The role of packaging in business has undergone a major
change, and it has today assumed a very major role. Traditionally, packaging was defined as the activities of
designing and producing the wrapper or container for a product. This definition is no longer adequate. Today,
packaging has emerged as a major technology in itself, which is highly complex and specialized, highly multi-
functional, cross functional and very application oriented. Corrugated paper board boxes are one of the safest and
efficient means of packaging and shipment of goods. Corrugated board consists of a flat layer of paper sheet (liner)
glued on one or both sides of a corrugated paper. The corrugated board is made by passing two layers of Kraft
paper through corrugating machine. One layer of paper becomes corrugated after being passed through the heated
rolls and other is brought into contact with it after the former having glued at tips. 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”. Similarly, board
can be pasted to form thicker boards i.e. 5-ply, 7-ply and 9-ply etc. Page | 9 Applications of corrugated board boxes:
The corrugated board boxes are being used for the packing of industrials as well as consumer goods. They are used
for packing of chemicals, drugs, tobacco, engineering goods, canned and bottled goods confectionary, textiles,
fruits, vegetables, potteries, footwear, glassware, medical instruments, photographic equipment and a number of
other products. Advantages of Corrugated Board Boxes:  Light in weight (freight advantage).  Cellular structure
with high compressive strength, resiliency & shock resistance.  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.  These boxes are re-usable

Commercial details I. HSN codes for the product Corrugated Paper Board and Boxes 1. 48191010 –Boxes of
Corrugated Paper and Paper Board 2. 48191090 – Cartons & Cases of Corrugated Paper & Paper Board II. NIC codes
for of the product of Corrugated Paper Board and Boxes 1. 17021 Manufacture of corrugated paper and
paperboard 2. 17022 Manufacture of corrugated paper board containers 3. 17023 Manufacture of card board
boxes 4. 17024 Manufacture of sacks and bags of paper 5. 17029 Manufacture of other containers of paper and
paperboard n.e.c III. Details of the Clusters: There are 19 identified Corrugated Paper Board/Packaging clusters
across the country. These clusters have been identified by MSME-DIs for carrying out various interventions under
the schemes of Office of DC (MSME) for their growth and sustainability. The list of the identified clusters along with
other details is placed at Annexure-I. IV. Scope for establishment of the units: The units can be established
anywhere in India after undertaking necessary local market & demand survey, subject to availability of necessary
infrastructure, manpower, raw material, etc. V. Data of registered Units: As per the data available on Udyam
Registration portal, 14,530 MSMEs are registered under the activity corrugated paper, paper board and paper
board containers manufacturing. Out of these MSMEs, 9034 are Micro, 5200 are Small and 296 are Medium
category. The Page | 11 State/UT-wise unit details are placed at Annexure-II. The prominent industries in the
manufacture of Corrugated Boxes are:

The Products & Services: The unit/firm is focused on manufacturing corrugated kraft paper board and boxes, which
are an essential material in packing of a product. The products are used for packaging and shipment of FMCG,
electronics, pharma, medical, textile, garments and other related products. The targeted customers belong to the
following sectors:  Food & beverage  Electronic goods  Home & personal care goods  Chemicals  Textile goods 
Paper products  Others (Pharmaceuticals, rubber, and tobacco) Sector-wise distribution of corrugated packaging in
India

The Process:

The boxes are made up of corrugated paperboard that is different from the rigid

paper called as cardboard. The boxes are used to hold things to protect it from

damaging and keeping it from leaking. Boxes are printed with important

information on them about what is inside or how to carry or move them. It is

carefully designed to insert, hold items in place so they won’t spill or be

damaged. Steps in Box Building Corrugating machine is designed to do

continuous process which brings together three, five or seven sheets of paper to

form single, double or triple wall corrugated board. Strongboxes can be made

from different layers like 3 layers or 5 layers of flutes. The first work is to mix

dry corn starch with water and other chemicals and push it into the corrugators

to spread on the corrugated medium as the layers of liner are added. A box can

be made by the corrugated board on a sequence of connected machines called a

corrugating line.

1. Corrugation: The corrugators are fed with reels of paper. The paper is

hardened with heat and steam which is passed between corrugating rolls. This

process gives the paper a flute shape (wavy layer) in the single facer. The roll of

paper is pulled between a pair of gear like cylinders called corrugating rolls.
This forms the paper into a series of particular waves. Glue is applied to the tips

of the flutes on one side at the right places and the flute tips are pressed against

a flat liner. This creates a corrugated board, i.e., a continuous sheet of flat paper

with fluted paper glued to it. The corrugated board is so stiff that it cannot be

rolled up; this is cut into flat sheets as per the required size to make the boxes

which has been ordered. The corrugated board are then arranged and set aside

so the glue can dry properly and after that it is sent to the next process.
2. Printing: A printing machine is used to print with bright colour ink. Use graphic designs

for self-supporting display feature like company name, logo, product information, etc.

3. Die-Cutting: Die cutting is used to cut or punch out the size and shape of corrugated

paper desired.

4. Stitching: Stitching is used to connect the lap and the end of the sheet of a corrugated

container with a metal wire.

5. Gluing: Gluing is like stitching but resign adhesive is sued instead of metal wire. Finally

the packed or bundled boxes are ready for dispatch.

Regular Slotted Container

Box Blank Showing Score Lines, Slots, and Manufacturer's Joint

 The process flow chart for manufacturing corrugated paper board boxes is given below:

Process Flow Chart for manufacturing of Corrugated Paper Boxes

Raw Materials

Paper Roll Glue

Corrugation Machine

Corrugation Board

Slitter Machine

Flexo Print & Slotter Die Cutting

Manual Slotting

Manual Print

Gum Pasting
& Stitching

Banding & Finished Carton

Quality Assurance & Specifications

Quality assurance and quality check are the part and parcel of every sub stage of the

process. The quality control process starts with the supplier who supplies the Kraft paper

which is used to make corrugated cardboard. Kraft paper should be smooth and strong. The

individual boards are checked randomly after corrugation. The quality check measures the

moisture in the liner and medium. In the manufacturing process, quality test is determined

by ensuring the glue strength, bursting strength, compression and highly accurate

dimensions. The flatness of the box board is tested by warp test which assures that each

board will travel easily through the machines. The final product/boxes are also checked

randomly for each batch of the production for quality check, i.e. for trimming, cutting,

printing the colour and bundling.

In India, Corrugated Fibre board Boxes for packing and transportation are manufactured to

meet the standards as per IS 13228:2006, as tabulated below:

 LIST OF REQUIRED MACHINERY AND EQUIPMENT
AND COST

Unit Pice Total cost (‘000 Birr)

Sr. No Description Qty.
(Birr) FC LC TC
1 Corrugator 1 134 134 - 134
2 Slitter Scorer 1 63 63 - 63
3 Printer 1 86 86 - 86
4 Rotary Slotter 1 71 71 - 71
5 Folder Gluer 1 52 52 - 52
6 Boiler 1 134 134 - 134
7 Fork lift(5-10 ton) 1 250 250 - 250
Total FOB - -790 - 790
Freigh, Insurance, - - 1 66 67
Bank charges,
handling charges,
etc…
Total CIF - - - - 857

INITIAL INVESTMENT COST

Sr. Total Cost

No. Cost Items (‘000 Birr)
1 Land lease value 490.0
2 Building and Civil Work 750.0
3 Plant Machinery and Equipment 857.0
4 Office Furniture and Equipment 125.0
5 Vehicle 200.0
6 Pre-production Expenditure* 312.0
7 Working Capital 83.5
Total Investment cost 2,817.4
Foreign Share 29
 ANNUAL PRODUCTION COST AT FULL CAPACITY ('000 BIRR)

Items Cost %
Raw Material and Inputs 405.40 36.95
Utilities 103.44 9.43
Maintenance and repair 20 1.82
Labour direct 116.64 10.63
Factory overheads 38.88 3.54
Administration Costs 77.76 7.09
Total Operating Costs 762.12 69.47
Depreciation 205.7 18.75
Cost of Finance 129.21 11.78
Total Production Cost 1,097.03 100

UTILITY REQUIREMENT & COSTS

Unit Total
Sr. Annual
Description Cost Cost
No. Consumption
(Birr) (Birr)
1 Electricity (120 KW) 57,600 kWh 0.474 37,303
2 Water (at the rate of 1.5 liters/min) 14,000 m3 3.10 43,400
3 Fuel oil (at the rate of 1.5 liters/min) 9800 Lit 3.34 32,732
Total - - 103,435

ANNUAL AUXILIARY MATERIALS AND COSTS

Sr. Cost in Birr (‘000)

No Description Qty (Kg) Unit cost
LC FC TC
(Birr)

1. Adhesive (starch) 1600.00 4.00 6.40 - 6.40

2. Inks and other finishing 200.00 115.00 23.00 - 23.00
 Chemicals
Total - - 29.40 - 29.40

MANPOWER REQUIREMENT AND LABOUR COST

Sr. Monthly Annual Salary

Job Position Qty.
No Salary (INR) (INR)
1 General Manager 1 2,000 24,000
2 Production Supervisor 1 1,200 14,400
3 Accountant 1 700 8,400
4 Maintenance Head 1 800 9,600
5 Personnel 1 600 7,200
6 Clerk 2 400 9,600
7 Secretary 3 500 18,000
8 Stores Head 1 500 6,000
9 Cashier 1 400 4,800
10 General Services 3 200 7,200
11 Guard 3 200 7,200
12 Operators 6 600 43,200
13 Assistant Operators 3 300 10,800
14 Technicians 4 500 24,000
Sub Total 31 194,400
Employees Benefit (25% BS) 48,600
Total 243,000

Plant & Machinery:

To manufacture corrugated boxes of 5-Ply semi Auto Corrugated Box line 100 Meters per
minute with specification of maximum width1800mm, design speed 120m/min with

stacking size W1800 X L 3500 X H 100-170 mm, with cutting & slitting precession of ±

1mm. The following are main machinery with their activity details.

1. Single Facer: The single facer machine runs at the line speed of 100m/min. Using

negative pressure type design helps the medium paper to press evenly and closer to the

surface of corrugating roll to have perfect forming and also get even gluing on the flute tip

to have perfect laminating of the single facer. Quick change rolls in 15 minutes, while

replacing the corrugated rolls, the whole complete set of additional rolls with cassette is

delivered into the machine by the carriage and matched with the hydraulic motor to be

fixed on the base of the machine by the hydraulic system. The corrugating rolls, pressure

roll, and glue roll are adopted with the high stability of the airbag control system, also with

pneumatic control buffer effect. Adopt glue width motorized dividing to match the paper

width. Digital readout for the gap between glue roll and doctor roll. The movable type glue

unit is convenient to clean and maintenance. Easy operation control system. Touchscreen

with a colorful drawing display operation state, easy and simple to handle. This machine is

having Built-inpre- conditioner with the proportional device for the medium moisture and

temperature adjustment.
2. Mill Role Stand: The structure is double rotary shafts with four arms, supports two

paper mill roll on both arms at the same time. Hydraulic control system for paper mill,

roller up–down, clamp–opening, centering or motorized clamp open and centering. Using

multipoint brake and automatic expansion springiness chucks, Reduce paper wastage was

effective width 1200 mm – 2800 mm. Maximum paper roll diameter: 1500 mm Maximum

Support Weight: 5T. Main axis: k 270 mm

3. Pre Heater: The diameter of preheated roller: 4600 mm, 4900 mm, 41100 mm.

Electro motion heating angle adjustment. Adjustable range is 360 degrees. The surface of

all rollers is well treated by grind and plated by hard chrome to ensure reel paper be

heated averagely. Adopt dishing seal or plat design. Simplex, Duplex, Triplex or quardplex

preheater according to requirement.

4. Over Bridge Conveyor: Effective working width: 1600 mm- 2500 mm, Max.

Working speed: 200 m/min 250 m/min, Max. Sheet length 3000 mm, min sheet length 500

mm., Max Stacking height 1400 mm. (stacking height not over triplicity of sheet width),

Automatic sheet stacking and side delivery, simplex or duplex down stacker structure,

Hydraulic Servo valve control of elevator deck, ensure stable and quickly stacking,

conveyor belt keeping synchronous with production line speed, keep stacking stable. PLC

Control system to follow production line speed , delivery paper sheet, control elevator deck

up and down, control back stop positioning clapboard to achieve automatic order change.

This machine can be connect with production management system to achieved order

change and order management., Adopt man – machine conversation and touch screen

display, easy operation.

5. Glue Machine (Double): The glue machine Design Speed: 250 m/min, Glue roller:

320 mm. Each of the glue rolls controlled by a separate transducer motor to ensure all rolls

run with the same pace also run singly, because each roll controlled by the separate

transducer, after the glue roller renewed, also ensure the roll run with the same speed by

transducer adjustment.
6. Double Facer: The double facer is also like single with added advantages like 2 air-

cushion hot plate, 3 air-cushion hot plate ,4 air-cushion hot plates and Adjustable air bag

press plate, Spring press plate Gravity roller.

7. Main Driver:
8. Slitter and Scorer (Servo): Automatic Synchronize with the corrugated line and

also get in line with manufacture management system. High Compatibility, high quality PLC

equipped composing the CNC system. There are three type of scores: Concave – Convex

(Single Wall), Concave – Convex (Double Wall) and convex- Flat, which can also be

alternated with electrical scoring can also be computer controlled with fine scoring results.

Thin tungsten steel alloy blade, Sharp and long life of over 8 million meters. Computer

controlled auto grinding and manual grinding also applicable. Alternative grinding the

blade when slitting the board. It can increase efficiency.

9. Single Helical Cut off: Design Speed: 200 m/min – 250 m/min, Effective width:

1400 MM – 2500 MM, Cutting Length: 500 mm- 9000 mm, cutting precision: +/- 1 mm

(Running at a steady speed). Helical Knives Structure with HSS knife edge, serration type

knife and scissor cutting with less shear force, to keep the knives long life. Print and behind

feeding adopt sun wheel, smooth transportation, and uniform pressure, avoid damage

paperboard. Adjustable high precision non- gap gear to ensure cutting precision and

running balance. Knife shaft made by quality forged steel material.

10. Down Stacker: Gantry stacking. Changing single time is 20 seconds, automatic

counting system synchronized with the production management system, change orders

automatically with high speed. During working with production manage control system,

and then wastes paperboard less than 700mm due to change order. AC servo control

movement allows stacking smoothly and tidily.

 Schedule of Implementation:

The Process: The boxes are made up of corrugated paperboard that is different from the rigid paper called as
cardboard. The boxes are used to hold things to protect it from damaging and keeping it from leaking. Boxes are
printed with important information on them about what is inside or how to carry or move them. It is carefully
designed to insert, hold items in place so they won’t spill or be damaged. Steps in Box Building Corrugating
machine is designed to do continuous process which brings together three, five or seven sheets of paper to form
single, double or triple wall corrugated board. Strongboxes can be made from different layers like 3 layers or 5
layers of flutes. The first work is to mix dry corn starch with water and other chemicals and push it into the
corrugators to spread on the corrugated medium as the layers of liner are added. A box can be made by the
corrugated board on a sequence of connected machines called a corrugating line. 1. Corrugation: The
corrugators are fed with reels of paper. The paper is hardened with heat and steam which is passed between
corrugating rolls. This process gives the paper a flute shape (wavy layer) in the single facer. The roll of paper is
pulled between a pair of gear like cylinders called corrugating rolls. This forms the paper into a series of
particular waves. Glue is applied to the tips of the flutes on one side at the right places and the flute tips are
pressed against a flat liner. This creates a corrugated board, i.e., a continuous sheet of flat paper with fluted
paper glued to it. The corrugated board is so stiff that it cannot be rolled up; this is cut into flat sheets as per the
required size to make the boxes which has been ordered. The corrugated board are then arranged and set aside
so the glue can dry properly and after that it is sent to the next process. Page | 19 2. Printing: A printing machine
is used to print with bright colour ink. Use graphic designs for self-supporting display feature like company name,
logo, product information, etc. 3. Die-Cutting: Die cutting is used to cut or punch out the size and shape of
corrugated paper desired. 4. Stitching: Stitching is used to connect the lap and the end of the sheet of a
corrugated container with a metal wire. 5. Gluing: Gluing is like stitching but resign adhesive is sued instead of
metal wire. Finally the packed or bundled boxes are ready for dispatch. Regular Slotted Container Box Blank
Showing Score Lines, Slots, and Manufacturer's Joint Page | 20 The process flow chart for manufacturing
corrugated paper board boxes is given below: Process Flow Chart for manufacturing of Corrugated Paper Boxes
Raw Materials Banding & Finished Carton Gum Pasting & Stitching Manual Print Manual Slotting Die Cutting
Flexo Print & Slotter Slitter Machine Corrugation Board Corrugation Machine Glue Paper Roll.

Plant & Machinery: To manufacture corrugated boxes of 5-Ply semi Auto Corrugated Box line 100 Meters per
minute with specification of maximum width1800mm, design speed 120m/min with stacking size W1800 X L
3500 X H 100-170 mm, with cutting & slitting precession of ± 1mm. The following are main machinery with their
activity details. 1. Single Facer: The single facer machine runs at the line speed of 100m/min. Using negative
pressure type design helps the medium paper to press evenly and closer to the surface of corrugating roll to
have perfect forming and also get even gluing on the flute tip to have perfect laminating of the single facer.
Quick change rolls in 15 minutes, while replacing the corrugated rolls, the whole complete set of additional rolls
with cassette is delivered into the machine by the carriage and matched with the hydraulic motor to be fixed on
the base of the machine by the hydraulic system. The corrugating rolls, pressure roll, and glue roll are adopted
with the high stability of the airbag control system, also with pneumatic control buffer effect. Adopt glue width
motorized dividing to match the paper width. Digital readout for the gap between glue roll and doctor roll. The
movable type glue unit is convenient to clean and maintenance. Easy operation control system. Touchscreen
with a colorful drawing display operation state, easy and simple to handle. This machine is having Built-inpre
conditioner with the proportional device for the medium moisture and temperature adjustment.

Introduction to Corrugated Boxes

Corrugated boxes are widely used packaging materials known for their durability, lightweight structure,
and versatility. Made from corrugated fiberboard—consisting of a fluted corrugated sheet sandwiched
between one or two flat linerboards—these boxes provide excellent strength and cushioning, making
them ideal for shipping and storing a wide range of goods.

First developed in the 19th century, corrugated packaging has become an essential part of global
logistics and commerce due to its cost-effectiveness and environmental sustainability. The fluted inner
layer adds rigidity and shock resistance, protecting items from damage during transit. Corrugated boxes
come in various sizes, thicknesses, and configurations, and can be customized to meet specific shipping
or branding needs.

In addition to their structural benefits, corrugated boxes are also recyclable and biodegradable, making
them a preferred choice for eco-conscious businesses. Their widespread use spans industries such as e-
commerce, food and beverage, electronics, and pharmaceuticals.

Corrugated boxes are the smart, sustainable choice for modern packaging. Engineered for strength and
reliability, they protect products from damage during shipping while projecting a clean, professional
image. Whether you're shipping electronics, food items, or retail goods, corrugated packaging offers the
perfect balance of durability and cost-efficiency.

Fully customizable with your branding and made from eco-friendly materials, corrugated boxes not only
safeguard your products but also enhance your customer experience. With options for size, thickness,
print, and structure, corrugated boxes can be tailored to meet your exact business needs—making them a
vital part of your packaging strategy.

ABOUT THE PRODUCT

Corrugated boxes are widely utilized in the packaging of various things from food and beverages,
chemicals, glassware and ceramics, paper, electronics, textiles, personal care and household products to
shipping etc. The list is endless. Thus, we can say that corrugated boxes are everywhere. You may have
them in your home and not even realize it, even the pizza you receive comes in a corrugated box and six
million tons of old corrugated boxes are recycled every year. Corrugated boxes are popular because of
their strength, durability, lightness, recyclability, and cost effectiveness. Since these boxes are made by
assembling three layers of corrugated cardboard sheets. These sheets assist in trapping air between them
which acts as a cushion for protecting the contents of the box. Due to these qualities and safety of
packaging items in corrugated boxes, they are used widely in the food industry. The growth in these end
use industries has propelled the demand for corrugated boxes worldwide. Moreover, the e-commerce
industry is experiencing strong growth on account of the convenience offered by online shopping such as
free shipping options, and hassle-free delivery and return policies. As online retailers use product
specific corrugated boxes to keep items safe from mechanical stress, it is positively influencing the
market growth. Apart from this, in order to launch improved corrugated boxes, manufacturers are
investing in research and development activities. They are also coming up with customized packaging to
widen their consumer base. India Corrugated Box Market is expected to reach over INR 63,000 Crore by
FY 2023. The demand for corrugated boxes is only set to increase with the coming years and till now
there is no replacement for this product. Moreover, since these boxes are environmental friendly in
nature as they are manufactured without the use of any harmful chemicals and can be easily recycled,
they are highly advantageous than other packing products.

Market Survey report for Packinging Industry and future scope

1. Global Market Overview

 The global packaging market is valued at approximately USD 1.69 trillion in 2025 and is
projected to grow at a CAGR of ~3–4% through 2034 Metro India+2Towards
Packaging+2imap.com+2.
 The sector is inherently cyclical, tied to consumer demand. While some firms face headwinds
from falling pulp prices, the ongoing sustainability wave—especially in Europe—is opening new
avenues

2. India – Market Size & Growth

 Packaging market size: USD 101 billion in 2025, projected to reach USD 169.7 billion by 2030
(10.7% CAGR) Mordor Intelligence.
 Materials mix:
o Plastic: ~42% share in 2024, growing SUV but facing regulatory push Credence Research
Inc.+3Mordor Intelligence+3Wikipedia+3.
o Paper & Paperboard: fastest-growing (12.2% CAGR) Credence Research Inc.+14Mordor
Intelligence+14Grand View Research+14.
 Formats:
o Flexible packaging dominates (≈54–65% share), particularly in food and FMCG segments
.
o Rigid formats also expanding, especially in food and e-commerce sectors
Wikipedia+14Verified Market Research+14Reddit+14.
 Segment size projection: Packaging forecast in India estimated to reach INR 8,620 billion
(~USD 104 billion) by 2028, growing 6.7% CAGR

3. Future Scope & Opportunities

The Indian packaging industry is poised for substantial growth in the coming years, driven by increased
demand from various sectors, including food and beverage, pharmaceuticals, and e-
commerce. Innovations in digital printing, smart packaging, and eco-friendly materials are also expected
to boost the market. The industry is projected to grow at a CAGR of 23% between 2024-2030.

7. 📅 5-Year Outlook (to 2030–33)

 India’s packaging is expected to nearly double in value by 2030, growing at ~10–11% CAGR,
outpacing global growth.
 Paper & paperboard and flexible packaging segments will be the fastest-growing.
 Smart and circular economy-aligned packaging will emerge as mainstream, not niche.
INDIA'S PACKAGING INDUSTRY: A
BILLION-DOLLAR
TRANSFORMATION BECKONS
India's Packaging industry is on track to outperform the global market significantly. While the global
Packaging market is forecasted to grow from USD 1,140 billion in 2024 to USD 1,380 billion by 2029,
according to data from Mordor Intelligence, India's industry is set to expand at a faster pace.

Recent research projects it will grow from USD 84 billion in 2024 to USD 143 billion by 2029, achieving
an impressive compound annual growth rate (CAGR) of 11%, underscoring India's rising prominence
and leadership in the industry. This robust expansion is positioning India to capture an increasing share
of the global Packaging market, with its share projected to grow by approximately 10.5% by 2029.

The Asia-Pacific region, which includes India, already dominates the global market with a 39% share,
followed by North America at 28% and Europe at 26%.
Market Dynamics: A Nuanced Picture

The sector's growth in India paints a complex picture of economic opportunity. Flexible Packaging,
commanding a dominant 65% market share, is anticipated to surge from USD55 billion to USD 94 billion
by 2029. This segment's rapid ascent is driven by a confluence of factors, including sustainability trends
and technological advancements. Meanwhile, Rigid Packaging, though smaller in market share,
promises equally robust growth, projected to expand from USD 29 billion to USD 51 billion in the same
period.

India's Packaging industry is on track to outperform the global market significantly. While the global
Packaging market is forecasted to grow from USD 1,140 billion in 2024 to USD 1,380 billion by 2029,
according to data from Mordor Intelligence, India's industry is set to expand at a faster pace.

Recent research projects it will grow from USD 84 billion in 2024 to USD 143 billion by 2029, achieving
an impressive compound annual growth rate (CAGR) of 11%, underscoring India's rising prominence
and leadership in the industry. This robust expansion is positioning India to capture an increasing share
of the global Packaging market, with its share projected to grow by approximately 10.5% by 2029.

The Asia-Pacific region, which includes India, already dominates the global market with a 39% share,
followed by North America at 28% and Europe at 26%.
Market Dynamics: A Nuanced Picture

The sector's growth in India paints a complex picture of economic opportunity. Flexible Packaging,
commanding a dominant 65% market share, is anticipated to surge from USD55 billion to USD 94 billion
by 2029. This segment's rapid ascent is driven by a confluence of factors, including sustainability trends
and technological advancements. Meanwhile, Rigid Packaging, though smaller in market share,
promises equally robust growth, projected to expand from USD 29 billion to USD 51 billion in the same
period.
5. RAW MATERIAL REQUIREMENTS

 Craft Papers

 Glue  Staples wire etc.  Packaging Material 6. MANUFACTURING PROCESS Calculation has been based on
single corrugated sheet pasted with one sheet of craft paper. Two paper reels are run together on corrugated
machine. One layer of paper becomes corrugated after passing through the heated fluted rolls and other is
brought in contact with the former having been glued at the tips. These two get pasted together and are wound
in rolls. These will be procured on job work. By cutting this roll with board cutters and gluing the corrugated side
on pasting machine. A double face board is produced by the 3rd ply of paper over it. This board is kept under a
sheet pressing machines for some time for setting of wet glued sheets. Similarly board to board can be pasted to
form thicker board i.e. 5 Ply, 7 Ply and 9 Ply etc.
TARGET CUSTOMERS As we got to know earlier that corrugated boxes are widely used in almost all
the industry for safe transportation but for this project we will be concentrating on just 6 products. These
products or rather industries are – 1) E-Commerce 2) Electrical Appliances 3) Chemicals & Drugs 4)
Food Products like Chips 5) Stationery Items 6) Textiles Industry/Product Size Price per Box Ply-Type
E-Commerce 10"X6"X2" 7.4 3 ply 10''x7"x2" 8.6 3 ply 5"x4.5"x3.5" 5.4 3 ply 8"x4"x4" 6.2 3 ply
7"x5"x4.25" 7.0 3 ply 5.5"x5"x4" 6.8 3 ply Electrical Appliances 18"x18"x16" 35 3 ply 18"x18"x16" 50
5 ply 16"X12"X12" 20 3 ply 16"X12"X12" 30 5 ply Chemical & Drugs 16"X12"X12" 20 3 ply
16"X12"X12" 30 5 ply 10"X10"X10" 11 to 14 3 ply to 5ply Food Products 18"x12"x12" 29 5 ply
18"x12"x12" 19 3 ply Stationery Items 15"x12"x10" 24 5 ply 15"x12"x10" 14 3 ply 4"x4"x4" 2 to 5 3
ply to 5ply 7"x5.2"x4.2" 3 to 4 3 ply to 5ply Textile 18"x12"x12" 29 5 ply 18"x12"x12" 19 3 ply

🔚 Conclusion

The packaging industry—especially in India—is at a transformative crossroads. E-commerce,

sustainable regulation, and consumer expectations are all accelerating innovation. Companies
strategically investing in automation, recycled materials, smart features, and circularity are best
positioned to lead in the next decade.

About Myself

I am Atul Mudholkar. I am Bechliore of Engineers in Mechanical Engineer pass out from Rastrasant Tukdoji
Maharaj Nagpur University in 2006 year. I have total 18 years of experience and 7 years of experience in as a
Design Engineer in Corrugated Box manufacturing. From the beginning I was too much interested in
manufacturing of corrof=gtesdedIn Earlier Days when I passed out

Introduction
EXECUTIVE SUMMARY 1.

Name of the Company: Sat Kabir Packging Solutions Pvt Ltd

Promoter(s): Mr Atul Mudholkar & Mrs Sarika Mudolkar

Address: Charoli Phata, Chakan, Pune 5.

Size of the Plot: 5000 sqft

Proposed Project to: Corrugated Boxes be set-up 9.

NIC

Type of Industry: Paper Packaging 10.

Major Raw Materials: Kraft Paper, Gum, Wire, Ink etc.

No of Employee: 10.

Name of Designation Quantity

Managing Director 1
Salesman 1
Technical 1
Worker 6
Electrician 1
Helper 2

Power Load: 60 KW

Documents required

Manchines Required

Quotation

INTRODUCTION Corrugated cardboard is generally used to make packing or shipping containers. Though there
are various other types of cardboard boxes available, corrugated cardboard boxes are the most suitable for
maintaining the safety of the object it is carrying, especially for long distance shipping purposes. This is because
they are made of corrugated paper, manufactured from fiber and is sandwiched by cardboard. This setup makes
it very sturdy and ensures the delivery of the articles that it is carrying with zero damage. While some corrugated
boxes are made out of plastic, the majority is limited to paper. Corrugated boxes confirm safety and protection
of the product being shipped. It also offers durability, cost effectiveness, lightness, strength and recyclability
which make it an ideal choice for merchandising and marketing of goods with ease. They are also known to have
a good stacking strength. Stacking strength refers to the pressure that is formed during stacking. This is a great
advantage for transportation. The stacking strength of the corrugated box also plays a vital role in providing
crush resistance and product protection. Corrugated is made of paper and has an arched layer, called "fluting,"
between smooth sheets, called "liner." This arched layer provides corrugated with a very high strength ‐to ‐
weight ratio.
The corrugated most commonly used to make boxes has one layer of fluting between two smooth sheets. But
there are many types of corrugated available, each with different flute sizes and thicknesses. Corrugated Paper
boxes are extensively used in the packaging of industrial as well as consumer goods. In some of products like
crockery, electronic items, automobile components, glass and cigarettes, pharmaceuticals, soaps & cosmetics,
biscuits, hosiery, toys, rubber & rubber products, refrigerator, cooler & fans, proper type of packaging becomes
very important. 2. MARKET POTENTIAL AND MARKETING ISSUES, IF ANY With the steady rise in the industrial
production, the demand for corrugated paper boxes increasing every year. These boxes have got distinct
advantages such as light in weight, easy to fabricate as per required specifications. The corrugated papers and
boards may also find market in the rural areas for packing of fruits & vegetables

Different types of Ply

1. INTRODUCTION
Corrugated cardboard is generally used to make packing or shipping containers. Though
there are various other types of cardboard boxes available, corrugated cardboard boxes are
the most suitable for maintaining the safety of the object it is carrying, especially for long
distance shipping purposes. This is because they are made of corrugated paper,
manufactured from fiber and is sandwiched by cardboard. This setup makes it very sturdy
and ensures the delivery of the articles that it is carrying with zero damage. While some
corrugated boxes are made out of plastic, the majority is limited to paper. Corrugated boxes
confirm safety and protection of the product being shipped. It also offers durability, cost
effectiveness, lightness, strength and recyclability which make it an ideal choice for
merchandising and marketing of goods with ease. They are also known to have a good
stacking strength. Stacking strength refers to the pressure that is formed during stacking.
This is a great advantage for transportation. The stacking strength of the corrugated box
also plays a vital role in providing crush resistance and product protection.

Corrugated is made of paper and has an arched layer, called "fluting," between smooth
sheets, called "liner." This arched layer provides corrugated with a very high strength‐to‐
weight ratio.
2
 The corrugated most commonly used to make boxes has one layer of fluting between two
smooth sheets. But there are many types of corrugated available, each with different flute
sizes and thicknesses.

Corrugated Paper boxes are extensively used in the packaging of industrial as well as
consumer goods. In some of products like crockery, electronic items, automobile
components, glass and cigarettes, pharmaceuticals, soaps & cosmetics, biscuits, hosiery,
toys, rubber & rubber products, refrigerator, cooler & fans, proper type of packaging
becomes very important.

2. PRODUCTS AND ITS APPLICATION

Corrugated is an extremely durable, versatile, economical and lightweight material used for
custom‐manufactured shipping containers, packaging and point‐of‐purchase displays, in
addition to numerous non‐traditional applications ranging from pallets to children's toys to
furniture

Corrugated Paper boxes are extensively used in the packaging of industrial as well as
consumer goods. In some of products like crockery, electronic items, automobile
components, glass and cigarettes, pharmaceuticals, soaps & cosmetics, biscuits, hosiery,
toys, rubber & rubber products, refrigerator, cooler & fans, proper type of packaging
becomes very important.

3. INDUSTRY OUTLOOK AND TREND

Does paper have a future in the digital age? Ultimately, it is a question best answered by the
needs of the consumers, but based on the global demand outlook; consumers still want
paper well into the 21st century. World demand for paper has doubled in the past 20 years
and it is forecast to double again by the year 2020.

Per capita consumption of paper & paper board in India at 5 Kg is very low compared to
other developing countries like China and Brazil. Therefore, despite the threat of paperless
transaction, scope for paper demand appears to be bright. In developed nations it is as high
as 160 Kgs per annum.
3
 The challenge for the Indian paper industry to meet the ever‐increasing demand of paper,
board and newsprint is getting crippled due to shortage of fibers in the country. The
future demand of paper is expected to grow from 13 MT at present TO 20 MT in 2020.
Demand for cream wove paper and Map litho paper is expected to increase by 7‐8%.
Demand for different kinds of coated paper has increased by 8%, duplex board has
recorded increase by 6.5%, kraft paper has registered a 6% rise in demand and newsprint
an impressive 10%.

4. MARKET POTENTIAL AND MARKETING ISSUES, IF ANY

With the steady rise in the industrial production, the demand for corrugated paper boxes
increasing every year. These boxes have got distinct advantages such as light in weight,
easy to fabricate as per required specifications. The corrugated papers and boards may
also find market in the rural areas for packing of fruits, vegetables & eggs.

5. RAW MATERIAL REQUIREMENTS

 Craft Papers
 Glue
 Staples wire etc.
 Packaging Material

6. MANUFACTURING PROCESS

Calculation has been based on single corrugated sheet pasted with one sheet of craft
paper. Two paper reels are run together on corrugated machine. One layer of paper
becomes corrugated after passing through the heated fluted rolls and other is brought in
contact with the former having been glued at the tips. These two get pasted together and
are wound in rolls. These will be procured on job work. By cutting this roll with board
cutters and gluing the corrugated side on pasting machine. A double face board is
produced by the 3rd ply of paper over it. This board is kept under a sheet pressing
machines for some time for setting of wet glued sheets. Similarly board to board can be
 pasted to form thicker board i.e. 5 Ply, 7 Ply and 9 Ply etc.

DISCLAIMER

The views expressed in this Project Report are advisory in nature. UP MSME
assume no financial liability to anyone using the content for any purpose. All
the materials and content contained in Project report is for educational
purpose and reflect the views of the industry which are drawn from various
research material sources from internet, experts, suppliers and various other
sources. The actual cost of the project or industry will have to be taken on case
to case basis considering specific requirement of the project, capacity and type
of plant and other specific factors/cost directly related to the implementation
of project. It is intended for general guidance only and must not be considered
a substitute for a competent legal advice provided by a licensed industry
professional. UP MSME hereby disclaims any and all liability to any party for
any direct, indirect, implied, punitive, special, incidental or other consequential
damages arising directly or indirectly from any use of the Project Report
Content, which is provided as is, and without warranties