1
Production Planning & Job Sheet Preparation
Customer order is reviewed and analyzed to determine box specifications (size, ply, GSM, quantity). A detailed job sheet is created specifying deckle width, cutting length, paper grades, and machine allocation. Production scheduling is done to minimize changeover time and maximize machine efficiency. Raw material availability is checked against BOM (Bill of Materials).
Tools: ERP Software, MIS Planning System, Excel / Production Boards
BOM AnalysisJob Card CreationMachine SchedulingMaterial Planning
2
Raw Material Receiving & Quality Inspection
Kraft paper, Test liner, and Fluting Medium rolls are received from suppliers. Each roll is inspected for GSM (grammage), burst factor, ring crush, moisture content, and visual defects like edge damage or winding defects. Papers failing quality standards are rejected or used for secondary purposes. Approved rolls are stored in the paper store with proper labeling.
Machinery: GSM Cutter + Weighing Balance, Burst Tester, Ring Crush Tester, Moisture Meter, Visual Inspection
GSM VerificationBurst Factor TestRing Crush TestMoisture Content CheckVisual Inspection
3
Paper Pre-Conditioning & Slitting
Paper rolls are pre-conditioned using steam/moisture to achieve optimum running temperature (100–120°C). Cold or dry paper breaks frequently and reduces flute quality. If deckle width adjustment is needed, rolls are slit on a precision slitting machine to exact width. Slit rolls are re-wound and labeled before being sent to the corrugator line.
Machinery: Pre-Conditioner / Steam Box, Paper Slitter, Rewinder, Edge Trim Collector
Temperature: 100–120°CDeckle SlittingMoisture Balance
4
Corrugation — Single Facer Operation
The fluting medium (medium paper) is fed through a pair of heated corrugating rolls (150–180°C) to form the wave-shaped flute profile (A, B, C, E, or F type). Simultaneously, starch adhesive (heated to 60–65°C) is applied to flute tips. The liner (bottom paper) is then bonded to the corrugated flutes under pressure, forming a 2-ply "single face" board.
Machinery: Single Facer Machine, Corrugating Rolls (Heated), Steam Boiler, Adhesive Tank & Applicator Roll, Pressure Roll
Corrugating Temp: 150–180°CAdhesive Temp: 60–65°CSpeed: 80–150 m/minFlute FormationStarch Bond
5
Multi-Ply Lamination — Double Facer (5-Ply & 7-Ply)
For 5-ply boxes, the single-face board from the single facer is bonded with a second liner (top paper) on the Double Facer. The hot plate section (160–175°C) provides heat and pressure for firm adhesion. For 7-ply construction, two single-face boards are produced and combined with three liners.
Machinery: Double Facer Machine, Hot Plate Section, Belt Press System, Adhesive Applicator, Tension Controller
Hot Plate: 160–175°CBelt Press SystemSpeed: 60–120 m/minEven Pressure Distribution
6
Slitting, Scoring & Sheet Cutting
The continuous corrugated board is slit to the required deckle width using rotary slitting blades. Longitudinal score lines are applied for folding. The board is then cut to the required sheet length using a cross-cut flying shear or rotary cut-off knife.
Machinery: Slitter Scorer Machine, Rotary Cut-off Knife / Flying Shear, Sheet Stacker / Conveyor
Deckle SlittingLongitudinal ScoringCross-Cut to LengthAuto Sheet Stacking
7
Printing — Flexographic / Digital
Corrugated sheets are fed through a flexographic printing machine for customer branding, product details, barcodes, and handling instructions. Water-based inks are used for eco-friendly output. Print quality (color, registration, sharpness) is inspected against customer proof samples.
Machinery: Flexographic Printing Machine (2–6 color), Anilox Rolls, UV Curing / IR Dryer, Print Registration System
Water-Based InksUV / IR Drying4–6 Color CapabilityRegistration CheckBarcode Printing
8
Die Cutting, Slotting & Creasing
Printed sheets are fed into a rotary die cutter which simultaneously cuts the box blank outline, forms slots, and creates deep crease lines for folding. Die cutting rules (steel blades) are embedded in a wooden die board.
Machinery: Rotary Die Cutter, Die Board (Steel Rules), Slotter-Scorer Machine, Skeleton Waste Stripper
Steel Rule DiesSlot CuttingCrease Line FormationWaste StrippingHand Hole Punching
9
Folding, Gluing & Stitching / Joining
Box blanks are folded along the crease lines using a folder-gluer machine. Hot melt adhesive (applied at 150–180°C) is used for the manufacturer's joint. Alternatively, wire stitching is done using a stitching machine with galvanized wire staples.
Machinery: Folder Gluer Machine, Hot Melt Glue System, Stitching Machine (Wire Stitcher), Bundle Counter, PP Strapping Machine
Hot Melt: 150–180°CWire StitchingPP Band StrappingAuto Bundle CountJoint Compression
10
Final Quality Control & Testing
Finished boxes undergo multiple quality checks: Dimension verification, Bursting Strength Test (BST), Edge Crush Test (ECT) for stacking strength, Box Compression Test (BCT), Moisture content check, and Print quality inspection.
Machinery: Bursting Strength Tester, Edge Crush Tester, Box Compression Tester, Digital Moisture Meter, Measuring Tape / Go-No-Go Gauge
Burst Strength TestECT / BCT TestDimension CheckPrint InspectionReject Quarantine
11
Packing, Palletizing & Dispatch
Finished boxes are counted, flat-packed, and bundled with PP straps. Bundles are stacked on wooden pallets and stretch-wrapped with LLDPE film. Weight slips, delivery challans, and quality certificates are prepared.
Machinery: PP Strapping Machine, Stretch Wrap Machine, Forklift / Pallet Jack, Weighing Scale, Label Printer
PP StrappingStretch WrapPallet StackingChallan & QC CertificateOTD Tracking
12
Production Analysis & Continuous Improvement
Post-production analysis evaluates material consumption, wastage percentage, machine efficiency (OEE), and cost per unit. Monthly reports are generated for management review. Kaizen and 5S practices are applied for continuous improvement.
Tools: Production MIS Software, OEE Calculator, Wastage Analysis Sheet, Cost Accounting System
OEE AnalysisWastage TrackingCost Per UnitKaizen / 5SDowntime Analysis
1
Material Selection & Quality Verification
Bottom paper (Kraft or Test liner) and flute medium rolls are selected based on required GSM and quality grade. Each roll is tested for GSM (grammage), burst factor, moisture content, and ring crush value. Approved rolls are pre-conditioned with steam to achieve optimal running moisture (8–11%).
Machinery: GSM Cutter & Balance, Burst Tester, Moisture Meter, Ring Crush Tester, Steam Pre-Conditioner
GSM VerificationMoisture: 8–11%Burst Factor CheckPre-Conditioning
2
Corrugation — Flute Formation
The flute medium is fed through heated corrugating rolls (150–180°C) to create the wave pattern. Steam pressure (8–12 kg/cm²) maintains the roll temperature for consistent flute height and pitch.
Machinery: Single Facer — Corrugating Rolls, Steam Boiler, Temperature Controller, Pressure Gauge
Temp: 150–180°CSteam: 8–12 kg/cm²Flute Profile Control
3
Adhesive Application & 2-Ply Bonding
Heated starch adhesive (60–65°C) is applied uniformly to the flute tips using an applicator roll. The bottom liner is then brought in contact with the glued flute tips under a pressure roll — creating a firm 2-ply bond.
Machinery: Adhesive Tank, Applicator Roll, Pressure Roll / Bonding Section
Adhesive Temp: 60–65°CViscosity: 35–45 secUniform ApplicationBond Pressure Control
4
Rolling, Winding & Core Formation
The 2-ply corrugated board (single face) is wound onto a cardboard or paper core tube on a rewinding machine. Winding tension is precisely controlled to avoid core deformation or flute crushing.
Machinery: Rewinding Machine, Tension Controller, Core Loading System, Roll Diameter Gauge
Tension ControlCore WindingDiameter MonitoringWeight Spec Compliance
5
Finished Roll Quality Inspection
Each completed roll is weighed on a platform scale to verify weight against the job order. GSM verification, flute profile check, and bond strength (peel test) are conducted. Approved rolls are marked with deckle, GSM, weight, and job number.
Machinery: Platform Scale, GSM Cutter, Bond Strength Test (Manual Peel), Visual Inspection
Weight VerificationFlute Profile CheckBond Peel TestRoll Labeling
6
Packing, Labeling & Dispatch
Approved rolls are wrapped in Kraft paper or stretch film for moisture and dust protection during transport. Each roll is labeled with GSM, deckle width, roll weight, job number, date, and destination.
Machinery: Wrapping Machine / Manual Wrap, Edge Cap Applicator, Label Printer, Roll Trolley / Forklift, Weighing Scale
Moisture ProtectionEdge Cap ProtectionGSM & Weight LabelChallan Issuance
1
Paper Selection & Width Preparation
Top paper, bottom paper, and flute medium rolls are selected based on plate GSM specification. All rolls are checked for GSM, moisture, and visual defects. If the deckle width does not match the plate width requirement, rolls are slit to exact width.
Machinery: GSM Cutter, Moisture Meter, Paper Slitter, Rewinder
GSM TestingWidth SlittingMoisture Check
2
Corrugation & 3-Ply Lamination
The flute medium is corrugated on the single facer at 150–180°C. The board then passes through the double facer where the top liner is laminated under heat (160–175°C) and belt pressure to complete the 3-ply construction.
Machinery: Single Facer, Double Facer, Hot Plate Section, Adhesive System, Belt Press
Single Facer: 150–180°CDouble Facer: 160–175°CBelt Press Bonding3-Ply Formation
3
Precision Cutting to Plate Size
The continuous 3-ply board is cut to the required plate length using a flying shear cut-off knife. Squareness (90° corners) is verified using a try square. Corner-to-corner dimension tolerance is maintained within ±2 mm.
Machinery: Flying Shear / Guillotine Cutter, Inline Slitter, Sheet Stacker, Try Square & Measuring Tape
Flying Shear CutInline Slitting±2mm ToleranceSquareness Check
4
Quality Inspection & Testing
Cut plates are inspected for dimensions, ply bonding (manual peel test), flute profile (finger-press test), visual inspection for warping, and surface quality for print-ability.
Machinery: Measuring Tape / Steel Rule, Try Square, Bond Peel Test (Manual), Visual Inspection Station
Dimension VerifyBond Peel TestFlute Profile CheckWarp Inspection
5
Bundling, Strapping & Dispatch
Approved plates are counted and stacked in uniform bundles secured with PP strapping bands. Bundle labels are printed with plate dimensions, GSM, quantity, and job reference. Delivery challans and quality certificates are issued.
Machinery: PP Strapping Machine, Corner Board Applicator, Stretch Wrap Machine, Label Printer, Platform Scale, Forklift
PP StrappingCorner Board ProtectionBundle LabelingWeight & Count RecordQC Certificate
