Professional calculators and comprehensive guides for corrugated box manufacturing, BOPP tape, paper tubes, timber, and packaging solutions. Expert tools for GSM calculation, box costing, flute specifications, and business insights tailored for packaging industry owners, engineers, and entrepreneurs in India.
Complete Manufacturing Process (Click to View/Hide)
Complete Box Manufacturing Process Step-by-Step
1
Job Sheet Preparation
• Customer requirements analysis
• Technical specifications finalization
• Material selection (GSM, ply type, flute type)
• Quantity planning and scheduling
• Cost estimation and pricing
Machinery: Computer Systems, Design Software, ERP Systems
2
Raw Material Preparation
• Kraft paper rolls inspection
• GSM verification and quality check
• Paper cutting to required deckle width
• Moisture content testing
• Paper storage in controlled environment
Machinery: Paper Slitter Machine, Moisture Meter, Quality Control Equipment
3
Corrugation Process
• Flute paper feeding into corrugating rolls
• Steam heating (150-180°C) to soften paper
• Corrugation using flute rolls (A, B, C, E, F flute)
• Starch adhesive application on flute tips
• Temperature and pressure monitoring
Machinery: Single Facer Machine, Corrugating Rolls, Steam Boiler
4
Board Lamination
• Liner paper alignment with corrugated medium
• Adhesive application (corn starch based)
• Pressure bonding between layers
• Multi-ply lamination for 5-ply and 7-ply
• Board thickness and quality inspection
Machinery: Double Facer Machine, Adhesive Applicator, Pressure Rollers
5
Conditioning and Drying
• Board passage through drying section
• Controlled temperature drying (80-100°C)
• Moisture adjustment to 8-10%
• Board cooling to room temperature
• Warp prevention and flatness control
Machinery: Hot Plate Section, Cooling Section, Conveyor System
6
Cutting and Creasing
• Board feeding into rotary die cutter
• Cutting to required sheet size
• Crease line formation for folding
• Slot cutting for flaps
• Scrap removal and recycling
Machinery: Rotary Die Cutter, Creasing Rules, Slotting Knives
7
Printing and Coating
• Flexographic printing for branding
• Multi-color printing up to 4 colors
• Varnish coating for protection
• UV curing for instant drying
• Print quality inspection
Machinery: Flexo Printing Machine, UV Curing System, Color Matching System
8
Slotting and Folding
• Slotting for flaps and joints
• Folding along crease lines
• Glue tab formation
• Automatic folding machine operation
• Manual folding for complex designs
• Loading on transport vehicles
• Invoice and challan preparation
• Quality certificate issuance
• Customer feedback recording
• Production data analysis
• Plate counting
• Bundling in required quantities
• Strapping for security
• Weather protection
• Labeling for identification
Machinery: Bundling Machine, Strapping Machine
Corrugated Products Job Sheet
Box C/Roll (2-Ply) Plate (3-Ply)
OD ID
Party / Customer Details
Box Specifications
C/Roll Specifications (2-Ply)
Plate Specifications (3-Ply Corrugated)
Box Construction
C/Roll Flute Type
Plate Flute Type (3-Ply)
Additional Production Details
Production Disclaimer
This Factory Job Sheet Calculator is designed for corrugated box manufacturing production units. All calculations are based on standard industry formulas and are provided as estimates for production planning purposes. Actual material requirements, cutting dimensions, and costs may vary based on machine capabilities, material quality, and production conditions. This tool should be used as a reference for production planning and must be verified with actual machine setups and material testing. The creator is not responsible for production errors, material wastage, or financial losses resulting from the use of this calculator. Always conduct proper quality checks and material testing before full-scale production.
