Box Manufacturing Calculator: Factory Production Cost & Efficiency Analysis

Corrugated Box Factory: Complete Production Management System

Factory Production Suite:
• Box Production: 3/5/7 Ply Corrugated Boxes with Complete Material & Cost Analysis
• C/Roll Manufacturing: 2-Ply Corrugated Rolls (Deckle & Weight Specifications)
• Plate Production: 3-Ply Corrugated Plates (Top + Bottom + Flute Construction)
• Deckle Wastage Analysis: Machine Efficiency & Paper Waste Calculation (Box Production Only)

Production Workflow:

1. Step 1: Select Product Type (Box/C/Roll/Plate)
2. Step 2: Enter Customer & Production Details
3. Step 3: Input Specifications (Dimensions/GSM/Quantity)
4. Step 4: Calculate Complete Job Sheet
5. Step 5: Analyze Deckle Wastage & Material Efficiency (Box Production Only)
6. Step 6: Generate PDF Production Report

Corrugation Plant Machine Specifications

Deckle Width Range (Standard)

670mm, 790mm, 840mm, 900mm, 1000mm, 1100mm, 1200mm, 1320mm

Cutting Length Range

950mm to 1850mm (Single/Dual Sheet Configuration)

C/Roll Production

2-Ply Rolls (Bottom Paper + Flute Medium) - Deckle in cm with Weight Specifications

Plate Production

3-Ply Corrugated Plates (Top Paper + Flute + Bottom Paper) - Length & Width Specifications

Flute Types Available

A-Flute (1.55), B-Flute (1.35), C-Flute (1.45), E-Flute (1.30), F-Flute (1.25)

Complete Manufacturing Process Flow

Box Production: 12-Step Manufacturing Process

1

Production Planning & Job Sheet

• Customer order analysis & specifications
• Material requirement planning
• Job sheet creation with all parameters
• Production scheduling & machine allocation

Tools: Computer Systems, ERP Software, Planning Software

2

Raw Material Preparation

• Kraft paper quality inspection
• GSM verification & moisture testing
• Paper cutting to required deckle width
• Material storage in controlled environment

Machinery: Paper Slitter, Moisture Meter, Quality Testing Equipment

3

Corrugation Process

• Flute paper feeding into heated corrugating rolls
• Steam heating (150-180°C) for paper flexibility
• Corrugation as per flute type (A/B/C/E/F)
• Temperature & pressure monitoring

Machinery: Single Facer Machine, Corrugating Rolls, Steam Boiler

4

Board Lamination

• Liner paper alignment with corrugated medium
• Starch adhesive application on flute tips
• Pressure bonding between layers
• Multi-ply lamination for 5-ply & 7-ply boxes

Machinery: Double Facer Machine, Adhesive Applicator, Pressure Rollers

5

Cutting & Creasing

• Board feeding into rotary die cutter
• Precision cutting to sheet dimensions
• Crease line formation for folding
• Slot cutting for flaps & joints

Machinery: Rotary Die Cutter, Creasing Rules, Slotting Knives

6

Printing & Finishing

• Flexographic printing for branding
• Multi-color printing capability
• Varnish coating for protection
• UV curing for instant drying

Machinery: Flexo Printing Machine, UV Curing System

7

Slotting & Folding

• Slotting for flaps and joints
• Folding along crease lines
• Glue tab formation
• Manual/automatic folding as per design

Machinery: Slotter Machine, Folder Gluer

8

Stitching/Gluing

• Hot melt adhesive application
• Stitching with wire staples
• Compression for bonding
• Joint strength testing

Machinery: Stitching Machine, Hot Melt Gluer

9

Quality Control

• Dimension verification
• Bursting strength test (Kgf/cm²)
• Edge crush test (ECT)
• Compression strength test

Machinery: Bursting Strength Tester, ECT Tester, Compression Tester

10

Bundling & Packing

• Box counting and bundling
• Strapping with PP bands
• Stacking on pallets
• Weather protection wrapping

Machinery: Bundling Machine, Strapping Machine, Pallet Jack

11

Dispatch

• Loading on transport vehicles
• Invoice and challan preparation
• Quality certificate issuance
• Documentation completion

Machinery: Forklift, Weighing Scale, Computer Systems

12

Production Analysis

• Material consumption analysis
• Wastage calculation & optimization
• Cost analysis & profitability
• Production efficiency reporting

Tools: Production Software, Analytics Tools, Reporting Systems

C/Roll (2-Ply) Production Process

1

Material Selection

• Bottom paper selection (Kraft/Test)
• Flute medium selection
• GSM verification
• Moisture content check

Machinery: Paper Testing Equipment, Moisture Meter

2

Corrugation

• Flute paper corrugation
• Temperature control (160-180°C)
• Flute profile formation
• Starch adhesive application

Machinery: Single Facer Machine, Corrugating Rolls

3

Bonding Process

• Bottom paper alignment
• Adhesive application
• Pressure bonding
• 2-Ply formation

Machinery: Bonding Machine, Pressure Rollers

4

Rolling & Winding

• Continuous winding on core
• Tension control
• Roll diameter monitoring
• Weight measurement

Machinery: Rewinding Machine, Tension Controller

5

Quality Control

• GSM verification
• Flute profile check
• Bond strength test
• Visual inspection

Machinery: GSM Cutter, Bond Strength Tester

6

Packing & Dispatch

• Roll wrapping in craft paper
• Edge protection
• Labeling with specifications
• Loading for dispatch

Machinery: Wrapping Machine, Label Printer, Forklift

Plate (3-Ply) Production Process

1

Material Preparation

• Top paper selection
• Bottom paper selection
• Flute medium selection
• Cutting to required width

Machinery: Paper Slitter, GSM Testing Equipment

2

Corrugation & Lamination

• Flute medium corrugation
• Top and bottom paper feeding
• 3-Ply lamination
• Adhesive application

Machinery: Single Facer, Lamination Machine

3

Cutting to Size

• Continuous board feeding
• Length cutting as per requirement
• Width cutting to size
• Squareness checking

Machinery: Guillotine Cutter, Sheeting Machine

4

Quality Control

• Dimension verification
• Ply bonding check
• Flute profile inspection
• Visual defect checking

Machinery: Measuring Tape, Bond Strength Tester

5

Bundling & Packing

• Plate counting
• Bundling in required quantities
• Strapping for security
• Weather protection

Machinery: Bundling Machine, Strapping Machine

Corrugated Box Factory Production Calculator

Box Production C/Roll Production Plate Production

OD ID

Customer & Order Details

Customer Name *

Product Description *

Box Specifications

Length (mm) *

Width (mm) *

Height (mm) *

Production Quantity *

C/Roll Specifications (2-Ply)

Deckle Width (cm) *

Total Roll Weight (kg) *

Plate Specifications (3-Ply)

Plate Length (mm) *

Plate Width (mm) *

Production Quantity *

Box Construction Details

Ply Type * Select Ply Type 3-Ply Box 5-Ply Box 7-Ply Box

Flute Type * Select Flute Type A-Flute B-Flute C-Flute E-Flute F-Flute

C/Roll Flute Type

Flute Type * A-Flute B-Flute C-Flute E-Flute F-Flute

Plate Flute Type (3-Ply)

Flute Type * A-Flute B-Flute C-Flute E-Flute F-Flute

Production & Cost Details

Paper Rate (Rs./kg)

Production Instructions

Deckle Wastage & Material Efficiency Analyzer
(Box Production Only)

Deckle Specifications Analysis

Required Deckle (mm) *

Machine Setting Deckle (mm) *

Product Weight (kg) *

Production Quantity *

Cost Impact Analysis

Paper Material Rate (Rs./kg)

Production Calculation Disclaimer

Important Notice: This Corrugated Box Factory Production Calculator is designed for production planning and estimation purposes only. All calculations are based on standard industry formulas and typical manufacturing parameters. Actual material requirements, cutting dimensions, production costs, and machine efficiencies may vary based on specific machine capabilities, material quality variations, production conditions, and operational factors. This tool should be used as a reference guide for production planning and must be verified with actual machine setups, material testing, and production trials. The system creators are not responsible for production errors, material wastage, financial losses, or operational issues resulting from the use of this calculator. Always conduct proper quality checks, material testing, and production validation before full-scale manufacturing.

For Production Use: Always verify calculations with actual production parameters and consult with production engineers before finalizing production plans.