April - June 2014
Opens up new levels of Speed, Efficiency and Productivity in Corrugated Packaging
We believe that successful installation of a plant is not the end of the deal - but the beginning of ‘Value - Partner Relationship’ which demands our attention to the customer on a 24X7 basis.
Beyond the Century in Corrugating Lines Over 126 Automatic Corrugated Board Plants Installed across India and Overseas
Delivering Value to Corrugated Box Manufacturers
Sun-Up (India) Packaging Machinery Co. Pvt. Ltd.
R-268. T. T. C. Industrial Area, Thane Belapur Road, Rabale, Navi Mumbai, 400 701 (India) Phone. +91 2760 6187 / 2760 6187 | Mobile: +91 98210 45985 Email: raunak@sun-upindia.com, sunupindia@mtnl.net.in | rsbhurjee@rediffmail.com
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From Single Facers and Creaser Slotters... to Flexo Printers and Rotary Die Cutters Always Ahead Than The Extant...
We make them productive and cost effective
High Speed Fingerless Single Facer ( Pneumatic)
Winner of PacMachine Award 2010
High Speed Single Facer (Mechanical)
Shaftless Reel Stand (Pneumatic)
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Always Ahead Than The Extant...
During over two decades of experience, we continue to “stay ahead than the extant” offering sound solutions to box makers in India and across the world. With machines that are designed to perform. From pre-sales service to installation and prompt after - sales service our relationship with our customers evolves into an ever lasting bond.
Sheet Cutter
As the future unfolds, we look forward to strengthening our technological skills and building machines that will exceed the expectations of our customers and stand at par with international standards of excellence.
Automatic Flap Gluer
SUN-UP (INDIA) MACHINERY CO. PVT. LTD. Regd. Office: 1 Suyog Industrial Estate, L. B. S. Marg, Vikhroli (W), Mumbai- 400 083 INDIA. Tel.: +91 22 2578 4819 / 2577 0822 / 6796 9666 Fax.: +91 22 2578 5985 | Mobile: +91 98210 93645 E-mail: sunupindiamachinery@gmail.com | dsbhurjee@gmail.com Always Ahead Than The Extant...
www.sun-upindia.com
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Content Highlights
Federation of Corrugated Box Manufacturers of India 138, Mittal Estate No. 3, M. Vasanji Road, Andheri (East), Mumbai - 400 059.
11 - Managing The Die Cutting Process
15 - Rotary Cutting Dies for Corrugated
E-mail: admin@fcbm.org
www.fcbm.org
Please address all correspondence to the Editors at:
43- FCBM News Major Panel (Top)
Minor Flap (Top)
Horizontal Score Lines
Editors
Major Panel Manufacturer’s Joint
R. Suresh S. T. Reddiar & Sons, Cochin streddiar@gmail.com
Dharmendra Pandya Viva Packaging Products, Ahmedabad vivapkg@yahoo.co.in
55 - Corrugated Liner Problems
Minor Flap (Bottom)
Major Panel (Bottom) Slot
59 - Automatic Case Erecting Standards and tolerances for Corrugated Cartons
65 - Honeycomb Paper Opens up a new era in Panel - Type furniture.
Design & Production:
Print Links Bldg. H-4, Flat No. 2 (Lawn side) Jankalyan, Bangur Nagar, Goregaon (West), Mumbai - 400 090. Tel.: 2877 2890 email: greycells.nani@gmail.com
75 - Spot Waste and Eliminate!
87 - 11 Ways to Turn Empty Boxes Into Fabulous Fun for Kids 107 - Industry News
Printed at: Rajesh Printouch, Mumbai
120 - Events 103 - Products Profile
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the Editors’ page
R. Suresh The second quarter of 2014 has been full of vibrancy and phenomenal changes. Elections brought in a decisive mandate with the new government at centre firmly in place. The decisive victory is enough to give Modi a free hand to formulate industry-friendly strategies and bring the country back on a high-growth trajectory and make India an easier place to do business in. The government is readying a Rs 10,000 crore venture fund for MSMEs in a bid to bolster the flow of funds to the sector that accounts for 45% of manufacturing activity and 40% of exports. This should surely benefit our industry. ************ Having endured the effects of the global financial crisis that began in 2008, the world economy is finally on the road to gradual recovery. At the same time, market demand for paper packaging products represented by corrugated packaging has continued to grow. Nevertheless, corrugated packaging still faces many challenges: overcapacity, lack of innovation, controlling production costs and talent cultivation among them.
Dharmendra Pandya The total output value of global packaging was USD 799 billion. That figure is expected to reach USD 824 billion.
Let us hope that this will trigger industrial growth and in turn increased demand for packaging.
As corrugated boxes represent the largest branch of packaging, the rapid development of this sector is very impressive. According to forecasts by the International Corrugated Case Association (ICCA), the global corrugated industry will maintain a 5% growth rate between 2013 and 2016. China and SE Asia, including Malaysia, Indonesia, Thailand and Vietnam, will see growth of around 10%; India is expected to see a rate of 12%. The size and growth rate in these markets far exceeds those of other markets.
The corrugated packaging industry has been at the cross roads since a few months.
************ Two great Packaging Exhibitions were held during this quarter. Interpack 2014 – the world’s largest Packaging Exhibition showcased many innovations that will catapult the role of packaging in the next few years. The Sino Corrugated South attracted record number of visitors. Our Federation led a large delegation. There is a great optimism in the industry and the markets, that India will soon be in the reckoning as one of the fastest growing economies.
On the one hand, there is demand depression, under capacity utilization, increased investments in auto plant, increasing price rises and costs hampering and even endangering the survival of our industry. On the other hand, there are new avenues like ecommerce and Retail Ready Packages opening up demand on a hyper scale. Both view points are presented in this issue. We are sure the Reports will be food for thought for all of us. This issue also features an interesting article on innovative use of ‘used’ corrugated boxes. Besides, there are thought provoking articles on die cutting, management of waste etc. We are sure the readers will find this issue as interesting as ever.
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President’s Message Dear Readers, The sign of things to come are already seen. After long years of instability and shaky alliances, we have a stable government at Centre – a government which means business. The empowering of secretaries and the mandate to clear projects speedily, the sensex soaring; FIIs maintain bullishness are some points.
Ramchand H. Arora
The promises of Finance Ministers to boost farm sector is yet another indicator for increased demand for packaging. There is a recent report that growth of exports has risen by 12% in May, the fastest pace of growth in seven months, on the back of improving demand in the developed markets and partly due to depreciation of the rupee against the dollar. The recent run of good numbers — from exports to core sector and auto sales — have also raised expectations of a better positive industrial growth. All this is good for propelling growth. The growth and the expected increase in production and agricultural growth will spur demand for packaging. ********** Our Industry has been facing severe problems due to increasing costs of paper and other inputs and general economic slump due to which there has been demand recession.
Our Regional Associations have been fairly active this quarter. Many associations held press meets to highlight the grave problem faced by the industry due to steep increase in prices of kraft papers. WICMA released their latest Technical Publication - a Research Project taken up by WICMA R & D Centre. Such projects will indeed help the members in understanding technical aspects. It will also project a professional and technically savvy image of our Federation. A large FCBM delegation visited Sino Corrugated South. It is indeed very nice of the Reed Exhibitions, to have organized an INDIAN DAY to felicitate and recognize the members of the FCBM delegation. Members of our delegation had an opportunity to witness new technologies, machines and developments. A few members led by SICBMA President Bala Vassudevan visited Interpack 2014 at Dusseldorf, Germany. The world’s biggest packaging show – Interpack Showcases many packaging innovations – which I am sure would have inspired ‘Bala’ to create more inspiring packages out of corrugated – as he had done at the Chennai Conference. I took the opportunity of visiting FCBM office in the first week of June. The meeting with our office bearers was quite meaningful. We reviewed the happenings in the industry & Federation and planned a road map for the period ahead.
A recent report that India’s Industrial Production jumped in April and exports are rising to a new high appear as positive signs.
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Managing The Die Cutting Process In this article, I want to go into some details regarding the whole concept of the Die Cutting process in Rotary Die Cutters. Our industry continues to change both its culture and business practices. Machine speeds have certainly increased while box designs continue to be more complex. Our customers have raised their standards for color, color management and of course “consistency”. They are also asking for more product information on their shipping containers as well as asking for actual pictures of their products (Spot Labels). We are now manufacturing boxes that are more functional with added features like slit/scores, perf /scores, tear outs and display windows. Internal product separation, added product support (Bliss Boxes) and boxes that offer aides in the opening process (Slit /Score Designs) are also becoming standards. In order to increase the performance of our Die Cut sections and respond to our customer’s demands, we first must now focus on delivering a proper “caliper” sheet to be Die Cut. The Cutting Die Manufacturers really have no idea as to the “actual” caliper of the sheet to be die cut other than the fact that the board is “B” Flute, “C” Flute or Double Wall. He is assuming some consistency in board caliper. His customer, the box plant, will tell him the design caliper for the particular order but he really will never know the caliper of the sheet that is delivered. Based on the design caliper, the die board is designed and built. It is now the responsibility of the production people in the plant to deliver that caliper sheet to be Die Cut. Proper caliper sheets will contribute to accurate register and clean edges. Controlled caliper will also result in consistency in scoring. We all know that both scoring profiles and scoring depths are critical for our customers. We have to deliver consistency in order that our customers’ case erectors perform to their
satisfaction. We as box suppliers should always pay close attention to these details. I would now like to discuss standards that should be identified and used in the manufacturing process. These are not the standards used by the die board manufacturer but the necessary features that the die board manufacturer needs to understand and implement so that the box plant can consistently produce die cut products. These standards should be openly discussed and reviewed with both the die board manufacturer and his customer. It is necessary that the box plant itself implements its own standards according to the design of the Rotary Die Cutter and the products that box plant manufactures.
Dick Target “On Target Consultants” should read properly for the crews so that they can easily read information on the wood such as Product ID, Zero Register Number, and Specific Information for that order. In many cases, the wording is up side down when the cutting die is mounted on the cylinder. This makes it difficult for the crews to read and follow the information.
The following are suggestions that I have implements over the years with great success. Everyone participates and then everyone wins. l The Lead Edge of the die board must be properly and clearly identified. The word “ Lead Edge” should be clearly marked either by Laser (1.5” [38 mm] high) or a proper company label as close to the lead edge of the wood as possible. This makes it easy for any operator, with or with out experience, to accurately identify the lead edge on cutting dies that are symmetrical or orders that have similar designs on both the lead and trail edges. l Letter Orientation: The cutting dies are generally mounted on the exit side of the die cut section. The written product information on the wood
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l The Center Line Marks will be clearly marked on the lead edge, trail edge and join line of every cutting die. This includes the lead and trail edge of the second piece of wood. The line must extend to the edge of the wood in all cases. Where possible, this line is to be no less than 2” (50 mm) in length. The will allow the operator to easily and properly align the centerline of the cutting die over the centerline (scribe line) on the die drum. This will also allow the operator to easily mount the second wood on a twopiece cutting die in the centerline position. It is important that the crews use standards in mounting tooling and identified centerline locations are certainly important. l The “Zero Register” Number must be properly located on the Lead Edge of the wood on the Operator Side. The Zero Register Number represents the distance from the centerline of the zero or first row of bolt holes on the wood to where the product begins. Please note: This dimension is not measured to the first knife. In many cases, the first knife is the trim breaker and not the point on the wood where the product itself begins. The zero row of bolt holes should be properly identified by the manufacturer and indicated next to the zero register number.
NOTE: Our preference is for the zero register number to be in whole numbers. When necessary, the zero register number can be in ½” increments when dictated by the product design. In the case of Metric numbers, the Zero register number will never be in numbers less than 1 mm. These numbers should match the scales on the Die Cutter in the customer’s plant. In some cases, the box plant will have different machine manufacturers and some of the dials may be in inches and some will be in mm. In this case, the Zero Register numbers should be represented in both measurements.
l Rubbering of any type must not be located over information or dimensions located on the cutting die. I see this frequently. My feeling is that if there is product information; tooling numbers, register numbers or tooling height information that the die board manufacturer feels it is important enough to burn onto the wood, then why would he covered up. l The Body of the box will be properly supported to assure dimensional stability. This means adequate support rubber throughout the open area of the cutting die. Dimensions between the lead and trail scores must be maintained through proper rubber support. l Rubbering on Cutting Dies is actually critical. Our die cutters are running at faster speeds today with complex designs. It is important that the type of rubbering, its location and its performance function be understood. We all know that transport rubber, ejection rubber and cell design criteria are essential tools in our manufacturing process and these thoughts should be reviewed and updated on a regular basis. l Bolt Hole Layout. This is an important discussion in the design and application of cutting dies. The rules of yesterday no longer count. Here is a suggested specification: There will be a minimum number of bolt holes in the wood every three rows around the circumference of the cylinder. There will also be a minimum number of bolt holes in the wood every 8 to 10 inches (200 mm to 250 mm) across the width of the cylinder. There must be an adequate number of bolt holes (this would include trim areas) located in the working area or busy area of each and every cutting die in order to assure firm contact between the steel rule and the cylinder. NOTE: This specification indicates an absolute minimum number of holes that are
to be supplied in these cutting dies. A Proper bolthole layout enables the operators to run the die cutter at optimum speeds. Just a note. Every time the die cutting function occurs, the steel in the cutting die wants to push the wood away from the cylinder and a proper bolt hole lay out assures that this will not happen. At 120 sheets per minute, this event occurs two times every second. We have to die cut clean, die cut accurately and consistently and proper bolthole arrangements will allow this to happen. The “operators” must also put a BOLT in every hole. It is a team effort that if properly done will allow the plant to be very competitive both in Quality and Manufacturing Costs. These manufacturing guidelines are certainly just basics in the box making process. We, as an industry, are frequently so busy serving our customers, we sometimes just overlook these very important points. I would suggest that every plant set meetings quarterly with their suppliers entitled “How are we doing? These meetings should be held with our cutting die, printing plate and ink suppliers?” We should review any changes that have occurred in our process so that our suppliers can be current. Let us work smarter and focus on the changes that are being driven by not only our customers but also our customer’s customers. Enjoy Your Job!!
Dick Target, owner of “On Target Consultants” based in Lower Gwynedd, Pa., has been in the corrugated industry for over 35 years. He has worked in 29 countries developing and guiding corrugated plants in lean manufacturing, vendor development and management training. He teaches Converting Short Courses for TAPPI and is an active member of TAPPI’s TCC (TAPPI Consulting Council). He can be reached at: dicktarget©gmail.com
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Rotary Cutting Dies for Corrugated We do not want to discount the personal touch‌ technical sales representatives moderate any new developments and monitor our ongoing business with our customers. At the IADD. FSEA Odyssey, I was asked to explain our particular manufacturing process in hopes that others would come for - ward and explain their processes. We envision developing a series of articles on the general processes used in our industry, for educational and informational purposes. The idea is to get people to talk about what they do, not to get people to give away their trade secrets. cutting die develops. A consumer has need for a product made from corrugated. A few examples might include a simple box (often called a shipping container), pizza box, partitions, inner packing, pads, free standing floor displays for the stores, counter displays, produce boxes, and the list goes on and on. Our industry is blessed with an ongoing need, as many food items are shipped in a corrugated box. People need to eat. Many consumer goods are shipped in a corrugated box, and people need to receive their products in an inexpensive satisfactory condition. Many people in the industry have an idea of rotary cutting dies but were intrigued to listen to some of the details. For instance the rotary diecutter was invented by Bill Ward in the early 1960s. We are soon coming up on the 50th anniversary of his invention and although many innovative improvements have emerged, we still have the same basic process of soft anvil rotary diecutting today. This article will to explain how rotary cutting dies (RCD) are ordered and produced. In particular, I will briefly discuss soft anvil rotary cutting dies for corrugated. I have to back-up a few steps to share how the need for a soft anvil rotary
A consumer contacts a corrugated design department to develop a sturdy box capable of delivering their product with possible graphics printed on the outside that will also identify as well as sell their product. Upon gaining an order from their customer, many details have to be determined. These details have very much to do with how this cutting die will proceed. Protection, stacking strength, cost comparisons, warehouse suitability and volumes are some of the factors to consider. One might compare this to all of the extras or add-ons one might consider when buying a new car or home. Details are worked out and the consumer agrees to purchase this cutting die for their
Joe Adkision Immediate Past President – IADD particular needs. The corrugated house sends the information to the diemaker Our dreams have been met if our customer the corrugated house, has made available all of the particulars we need to professionally produce this cutting die, sometimes referred to as a dieboard or cutting tool. In particular we need a purchase order (P0) along with a computer aided design (CAD) file and a specifications sheet (SPEC). In our modern world these documents are quickly and simply emailed but can be physically placed in the hands of a sales representative if eye to eye discussion is needed. Time is of the essence, so we prefer the email route. However we do not want to discount the personal touch, as we continue to dispatch technical sales representatives (TSR) on a timely schedule to moderate any new developments and monitor our ongoing business with our customers. In our exchange we need a vast amount of information that can be exchanged in the three items I mentioned above. We need to have all of this information, as not having it can cause this particular cutting die to be produced incorrectly. Rather than that, we want to produce every cutting die to our mutual satisfaction. Vital information includes who, what, when, where and why If the bits of information above are
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developed, we can confidently proceed. If not, the process slows down and we have to start digging for this vital information. We will need more phone calls and more emails. (see Diagram 1) The purchase order can provide the contact person, the ship to and bill to address, predetermine how it will ship (common carrier, deliver, customer pick-up), when the tool is required in their plant, any pricing information, the freight agreement, FOB destination, and best of all the purchase order number we need to initiate the billing process. Sadly this process is often not initiated even in the face of realizing it makes good sense as we are told to never get started an order without an official purchase order. I believe it would make good business sense to work on this to the satisfaction of both parties, as not sending a purchase order until clays after the fact creates an unnecessary burden on both parties, requiring unneeded follow up calls and exposing both parties to needless mistakes. If we receive this fact-filled written Purchase Order, we are well on our way if in the same five minute time frame we receive the CAD file in addition to the specification sheet. Our customer service representatives (CSR) can quickly place this order in process. The CAD file can provide the actual dimensions. The SPEC provides the actual Lead Edge, the number out, up, over, any nesting or general information of our customers instructions. The SPEC designates the cut, score, per!’, etc; profiles and explains where they want them to appear on the RED. Again, I want to stress that we all need to communicate. In the absence of good communication, many mistakes are made, and both parties suffer. With all of this good communication, our CSR scrambles to make sure we have a good plan moving forward and that we have all of the information we need and we understand totally our customer’s wishes. A work order (W/O) is then created on our system using software anchored to our server for ongoing continuity and for real
time changes known to all parties. This is a major help to downstream activities. This information is passed to our CAD department to manipulate just how we will introduce this information to our lasers (see Diagram 2). We take the file and look it over for any opportunities we may introduce and create a scrap and bridging pattern. Without bridging, our dieboard (D/B) would simply fall apart like a jigsaw puzzle. W e also create a pattern of knives necessary to chop up the trim and scrap, sending it up the waste blowpipe to the baler while sending the finished product up the stacker to be later unitized for shipping or further processing (folding and gluing).
We next have to take all of our experiences and use some geometric calculations to determine our layout scale. We do our best, but this is at best a calculated risk using theory and experience to predict how to scale our D/B(determine our zero line and our finished size line). It was once described to me that you are sending a moving piece of paper through a machine that has a top moving cylinder and a bottom moving cylinder. Further the make up of the layout sends uncertainty through the process. Void areas on the layout all the way up to a high concentration of rule have an effect on the finished product sheet size. Perf pulls longer than score. Doublewall tends to cut shorter than singlewall, given
the same cutting die scale. Please refer to Clint Medlock of Stafford Cutting Dies’ article originally published in The Cutting Edge, April 1997, “Achieving Rotary Diecut Accuracy.” This is also available to IADD members on the IADD website at www. iadd.org. Our website holds tremendous educational information written by industry experts in many fields. In addition our TechTeamTM continues to serve answering technical questions from our industry. Take a look. When the CAD room completes an order, we put another set of eyes on the file to insure compatibility on the lasers. The laser operators have already pre-screened the order and have prepared the proper size of D/B through and across, then proceed to burn the laser kerfs through the wood (see Diagram 3). In this same time frame the ruling department has picked up the order and prepared for the rule processors the precut and pre-bent rule utilizing the CAD file, work order and spec sheet (see Diagrams 4 and 5) All of this material is presented to the rule installation department. The D/B is mounted on a ruling cylinder, placing a bolt in every hole to make sure that all bolts holes line up and for installation and proper fit of the rule into the laser kerfs. Special care is needed to insure that all cut, score and perf are correctly installed in the designated places (see Diagram 6). All rule joints are to be tight and properly seated, giving a familiar sounding thud on the ruling cylinder. While preparing this article, I have been to the website frequently, consulting numerous articles written by industry experts: rotary rule selection, proper scrap size, converting corrugated material, soft anvil rotary stripping, rotary die knifing. rotary D/B’s, proper mounting of D/B’ s. fracturing/cracking scores, flat crush on rotary D/B’s, and last but not least improved rubbering techniques and state of the art ejection materials. Upon rule completion, the D/B is sent to our rubbering/ finishing department.
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Serving the Corrugated Packaging Industry Since Five Decades
H-350 Fingerless Single Facer
Single / Double wall Corrugator
Make Sure It’s
The Symbol of Quality in Corrugated Machinery
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HSL-2 Hydraulic Shaftless Mill Roll Stand
50 YEARS IN THE SERVICE OF CORRUGATED PACKAGING INDUSTRY
HD-180 Dual Flute Single Facer
We double check all components to our W/O and quality sheet as it compares to our customer’s specification sheet. When all is right about this order, it’s ready to go into a shipping container and/or routed according to our customer’s wishes.
incorporated into the rotary cutting die, I still believe that the lifeblood of an RCD is the ejection material. We need to eject the finished product off of the die up the stacker, sending the scrap up the blowpipe. Numerous opinions have been developed and ejection has very much to do with the people, product, machine, and condition of the paper on press day All of these things, when mastered, can help us achieve our desired results. How we all react to these conditions helps us further define how we will manage our process. If you are experiencing a good quality finished product off of your equipment, keep up the good work. Help is available throughout our industry; all you have to do is ask.
In a plant seminar I recently gave, it was stated to me by my customer that they were doing a great job and that they were making money, but that there was always room for improvement. They further challenged me to continue our R&D, stating that we were in a world of “thirty/seconds” and they were willing to try subtle changes to see if further improvement was possible. How could I turn down an offer like that, especially since they told me they would monitor the process and share the results of the minor tweaks with our team? This is a great opportunity for us, for all of us. It has been said that 50% of all damage to an RCD happens to and from the diecutter. Please be careful with these expensive tools and store them in a sturdy die rack. Please understand that from a safety standpoint these tools can cut you, so be very careful. Please work with your die maker for better results. As I stated at the beginning of this article, I would like to start a series of articles with industry experts including pressmen and personnel all up and down this industry
Numerous techniques include the installation of state of the art ejection components mixed in with some common sense craftsmanship, as well as any special customer instructions to be placed on our tools (see Diagrams 7 and 8). We perform the necessary techniques to insure proper stripping in our customer’s plant and mount the tool on our diecutter. We cycle the diecutter using the specified corrugated to determine 100% stripping and the required finished product sheet size (see Diagram 9). I saved this for the end as this has been my career position. When all of the previous quality details have been properly Cont. on Page 23 The Corrugator | April – June 2014 | 19
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Cont. from Page 19 whom I consider industry experts, to come forward to explain their processes. I am willing to help if you need it. I can tap keys on a keyboard. This not limited to anyone or any specific part of the industry. How is a rule processor created? How do you set up a diecutter? How are ejection materials and rubber made? We may have an idea how things are made but does it compare to how things are done currently 2010? How is steel rule cut, score, perf made? How are embossing, debossing dies made? How are punches produced with such accuracy? How are dieboards made? How do you get them to bend without breaking? How do you...? You fill in the words. Whose heart did I touch?
Joe Adkison now serves as Immediate Past President of the IADD. He is a previous recipient of the Presidential Award, the prestigious PEAKA Award and a previous Task Force chair of Odyssey. Joe has conducted seminars in many of our southern states as well as internationally. You may contact Joe at Adko, inc. in Fort Smith, AR, USA at 1-479646-2533 or by email: joe@goadko.com.
This article is reprinted with permission from the International Association of Diecutting and Diemaking’s monthly magazine, The Cutting Edge. The ADD is an international trade association serving diecutters, diemakers and industry suppliers worldwide. IADD provides conferences, educational and training programs, a monthly magazine, online resource library of 450 + technical articles, industry experts to answer technical questions, publications and training manuals, recommended
specifications, online used equipment marketplace, videos and more. IADD also co-presents Odyssey, a bi-annual trade show and innovative concept in technical training featuring a handson Techshop where training programs come alive in an actual working diemaking and diecutting facility inside the exhibit are. Visit www.iadd.org or call 1-815-455-7519 for more information about IADD.
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Specification of Corrugated Fibreboard Boxes for Packaging of Fruit & Vegetables l Packaging is the vital component of post harvest management
of fruits and vegetables. It helps in minimizing deterioration during handling and marketing of fruits and vegetables. l Adequate packaging protects the fruits and vegetables from physiological, pathological and physical deterioration and retains their attractiveness. l Packaging is required to keep fruits, vegetables and root crops in good condition until these are sold and consumed. l Packaging serves as an efficient handling unit to carry produce from field to consumer. l The package should also protect the produce against rotting. l Packages must also protect the produce against possible damage. Two main functions of packaging are: 1. To assemble the produce into convenient units for handling. 2. To protect the produce during distribution, storage and marketing. Corrugated Box continues to be the most preferred mode of Packaging because of its versatility, strength, costeffectiveness and eco-friendliness. As shipping container or secondary package the CFB box has few rivals. Major End Use Applications: l Textiles l Processed foods l Pharmaceuticals l Cosmetics, Soaps, Detergent & Toiletries l Engineering goods l Distilleries and breweries l Home Appliances l Fresh fruits, Vegetables, Cut Flowers l Tobacco Products l Electrical and Electronic Goods l Others
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(Mrs.) S. H. Bandekar Deputy Director ( R & D ) Indian Institute of Packaging, Mumbai
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Put the Seal of Quality on Your Packaging
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ECO Digi Model Double Head Model
Bursting Strength Testers Bursting Strength is a widely used measure of resistance to rupture in various packaging materials like Paper, Paperboard, Corrugated board, Nonwovens, Textiles, Geotextiles, Films, Tissues etc. Models : l Standard l Super l Double head l Eco Digi l Micro digital l Micro print l Micro PC l Available in two measuring ranges : 0-5 to 0-75 kg/cm2.
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Hand held Digital Moisture Meter imported from Germany for instant moisture results.
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Compression Tester Four Models : l Micro Print PC l Micro Print
(Microprocessor based Model with Printer Port) l Micro Digital l Touch Screen
Display Micro PC
Tensile Tester Suitable to test tensile strength of paper, films, foils, rubber etc. Available in capacities ranging from 1gm. to 1000kgs. Various tests like tensile, adhesion, peel (90/180 degree) can be performed.
Tear Tester Measures the force required to tear multiple sheets of paper
Winner of Pacmachine 2008 Award Compression Strength of a Box, Container, Tube, Drum, Bottle etc., gives a reliable indication of the overall performance of the package - besides indicating its ability to resist external compression loads during transit and storage. Linux Compression Tester – MicroPC Touch Screen Model is an Indian Industry First and can be used for testing of Packages for stacking load, transit load bearing capacity.
Cobb Tester Puncture Resistance Tester Five different scales to analyze materials of variable thickness.
Determining water absorptiveness of papers, boards etc.
Crush Tester For testing paper, corrugated board and its components as well as performing compression tests on small packages.
Winner of Pacmachine 2006 Award
Vibration Tester Simulates the conditions that occur on a package during transit. Gives an indication of the ability of the package to resist such transit stresses and protect packed products.
Suitable to measure : Flat Crush Test (FCT), Ring Crush Test (RCT), Edgewise Crush Test (ECT), Pin Adhesion Test (PAT), Concora Medium Test (CMT) and Corrugating Crush Test (CCT).
All Linux equipments conform to National Standards (IS, FCBM) and International Standards (TAPPI, ASTM, ISO, BS, AS/NZ, SCAN, DIN, etc.) Calibration traceable to National Physical Laboratory.
Instrumental in Your Success Rub Tester To measure the rub proofness of prints on paper or board. Can also be sued to measure colour transfer from printed or coated materials during rubbing.
Drop Tester Determines the performance of a packed box during handling and transportation.
Linux Machines Incorporation
Plot No. 3, Ahad Industrial Complex, Near Bharat Gears Ltd., Bholenath Nagar, P. O. Dawla, Mumbra, Thane - 400612 Tel. No. : +91 22 2549 4940 / 52, 088794 97458 Email: machines.linux@gmail.com | www.testingequipments.com
The Corrugator | April – June 2014 | 37
Corrugation industry upgrades not working Modernization is more than machines The corrugation industry in the country needs to change not only by investing in automated plants but also in other ways that can make these investments sustainable. There are thousands of ordinary plants and while as many as two hundred have invested in automated plants from China and Taiwan, there is no guarantee of success for them. “The expectations to achieve better prices through improved productivity and better quality control is just not happening,” says Milan Dey, President of Eastern India Corrugated Manufacturers Association (EICMA) and also the owner of Madan Packaging in Kolkata. “We are trying to improve awareness across the industry and asking members not to indulge in destructive price wars, but have not yet succeeded.” Dey says that in the last five years, 16 automatic plants have been installed in the eastern region leading to over capacity and low capacity utilization. His own company which imported an
Indian corrugators need better understanding of quality and future trends before making capital investments in machinery
automatic corrugator from China in 2011 produces only a quarter of its installed capacity. Perhaps, as one local expert says, “The problem is that the so-called automated plants are only capable of producing more of what the thousands of plants which are less automated can produce and thus they cannot command a price to make them sustainable.” Although many of the larger companies operating in India understand the difference between a brown box and a logistically viable corrugated box, the overall awareness is poor. The investment in producing quality corrugated boxes is fairly large in terms of industrial built-up space, machinery, technology, appropriate raw material sourcing and best manufacturing practices, apart from the environmental considerations that are important to consumer product companies.
To run a corrugation plant without an effluent treatment plant is not advisable — nor can one simply source liner, adhesives, chemicals or coatings from non-standard suppliers. There is a lack of understanding of the needs of large FMCG companies and export clients and little investment has been made in testing raw materials, processes and end-products. Thus apart from the know-how needed to produce quality corrugated boxes, investments in marketing and product planning are also needed.
In fact, the investments of the organized producers of corrugated boxes are far ahead of the market as a whole. The high quality corrugation and flexo printing capacity of companies such as multilocation Horizon Packaging, Astron and Parksons Packaging are sustainable because they are looking at the specialized and high quality local and overseas requirements of their customers.
This feature has appeared in Packaging South Asia, June 2014. Reprinted with permission from the publishers. Our grateful thanks to them.
38 | The Corrugator | April – June 2014
Door Delivery Boxes The emerging e-tail market opens new avenues for corrugated boxes.
– A Report
After the retail – ready packages, it is emerging e-tail market that is opening up a new avenue for corrugated boxes. Following the Retail revolution there has been a great demand for retail – ready packages. Corrugated boxes fits the bill by virtue of then being versatile, and their ability to be tailor made and designed for on-the shelf packages. In the last few years the e-commerce has been growing at a rapid pace. The vibrancy of Flipkart, Myantra, e-bay and other players burgeoning in the e-tail space has generated a new way of shopping for the new generation. The delivery end of the e-tail chain calls for packaging that need to be innovatively designed for a variety of products. Besides being lightweight(to reduce freight costs) the packages should ensure safe transit of the product and at the same time the package should project a neat and professional look in keeping with the image of e-tailer. While this new avenue had a choice using different modes of packaging – the corrugated box came out a winner by virtue of its unique advantages. Today the speedily growing e-market is in turn creating a never before seen demand for well designed innovative boxes.
This utilitarinan item has become the symbol of India’s economic boom. Since a few years the corrugated box has been seen as a delivery package for home delivery of pizzas. The innovative and patented vented box ‘Ventit’ created by Mr. Vinay Mehta ensured that pizzas are delivered hot at your door! And today we see the so called ‘Brown box’ as a delivery package in the TV ads of Flipkart, Jabong, Amazon, etc.
One of the most recent and interesting ads is the journey of a box from a fulfillment centre to a stadium where a cricket ball is taken out of the package to get the Match Started! Over the years, the boxes used for shipments have become better and stronger to protect the range of small to high-end products like mobilephones, cameras, jewellery, etc. As the on-line retail takes strong root in India, it has triggered a business resurgence for corrugated box makers who can fit the needs of e-tailers. In an interview to a business daily, Mr. Kirit Modi – A leading box maker said that ‘almost 10% of box makers’ annual business is expected to come from ecommerce companies in the next 5 years. The requirements of ecommerce are varied and complex. The boxes need to be made in 40 - 60 different sizes.
The Corrugator | April – June 2014 | 39
40 | The Corrugator | April – June 2014
The rules of the game are also changing Mr. Sanjay Rajgarhia. A leading box maker in Delhi. said in the interview that ‘Until recently, e-commerce companies including market-leader Flipkart used to purchase the containers from small vendors as their requirements weren’t too substantial. But with Flipkart currently shipping around 5 million orders monthly and growing fast, the company is looking to get regular supplies from established manufacturers’. Another New Delhi based box maker received its first order from a ecommerce company for 12-15 lakh boxes per month. This made the online retailer the box maker’s top client dislodging our established MNC. Ecommerce has made things very interesting to box makers across India. That’s good news for the manufacturers as growth has been sluggish over the last few years due to the economic slump. The size of India’s e-retailing market is about $2 billion and is expected to quadruple in the next two years to more than $8 billion. In the words of Mr. Kirit Modi of Pyramid Packaging, Bangalore. “Box Makers should be ready to cater to e-commerce. E-commerce will be as big for boxes, as the consumer goods industry.”
The Corrugator | April – June 2014 | 41
In this context it is interesting that The Corrugator in the Jan.-Mar.- 14 had featured an article by Mr. Kevin Karstedt. On Page 79 he says that ‘Packaging is a big issue for on line merchants. Online shopping is the fastest growing retail segment. Packaging is a big issue for online merchants, as consumers frequently object to receiving their product simply placed in a plain shipping container. The objection is based on the consumer perception of the retailer lacking permanence or staying power, and potentially disappearing immediately after the sale. Online retailers are attempting
to promote brand identity, and a stronger connection between the online web site and packaging. The need for brand identity must be tempered with the reality of the shipping world, and the need to ‘safeguard’ the identity of the contents being delivered. This creates multiple opportunities for corrugated packaging, from smart packaging for tracking and tracing of shipments, to shipping containers, to high impact primary packaging.
“Subscription E-commerce” could be next big thing Technology makes everything pretty – even cardboard boxes Joseph Flaherty There is no better proof that we are living in a golden age of design than the fact that a simple cardboard box can be an object d’art. In the recent past, online shopping market has brought forth a renaissance in the craft of corrugation. For those unfamiliar with the term, subscription ecommerce is basically a “fruit-of-the-month club” where you get cosmetics, shoes, or other goods mailed to you every month instead of
42 | The Corrugator | April – June 2014
grapefruit. The model has exploded based on some early success like Birch Box and StyleMint and is spreading into a variety of other product categories. Luxury subscriptions bring a bit of random fun into the life of the customer and provide a steady revenue stream for the merchant, but also create a new set of challenges like creating a brand image with few touch points. With these services the brand is paramount. As a customer you are paying people to choose products for you, sight unseen. With no physical store to set the mood, retailers can only rely on their websites and shipper boxes to build the brand.
Packaging is now a major part of the “value add” and is the primary way to assure customers that they have made a smart decision trusting the taste/style of a given merchant. Fortunately for customers, this has made getting a package in the mail even more fun. Because of their market dominance and reputation for low prices, Amazon hasn’t really done much to dress up their boxes in over 10 years. They have a dominant position in the industry and a reputation for operations and delivery so a simple box fits their brand well.
FCBM News
MPCBMA Holds its Meet MPCBMA held its meeting on 8th May 2014 at Hotel Radisson Blue, Indore. The meeting was well attended by the members. The President appraised the members about National level scenario of Kraft paper prices, FCBM 2nd M.C. held at Hyderabad & other matters. All members agreed that MPCBMA should release a circular to all its members in which the impact of price rise on RM, Labour, Power & Freight should be shown in table form. Senior members expressed their concerns about increase in supply capacity against lower demand in finished products in the region.
customer meet and showcased their product together with infrastructure & Quality Testing Facility. They also thanked all members for supporting them & announced that they will be opening their direct marketing office in Indore very soon. Astron Paper & Board Mills was represented by their directors Shri Kirit Patel, Shri Ramakant Patel & GM Marketing Shri Shakti Bhargava. The Astron Paper customer meet concluded with dinner & cocktails.
After the meeting, Shri Ramkumar Sunkara gave presentation on choosing the right type of paper to get required ECT & C.S.. He also shared the points in process flow chart responsible for getting less C.S. The seminar was well attended by members & Regional paper mill owners. All the paper mill owners agreed to set up Lab to check Moisture, COBB, RCT etc. In the third session, M/s. Astron Paper & Board Mills, Ahmedabad held their
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44 | The Corrugator | April – June 2014
WICMA WICMA releases a Technical Publication At the WICMA Managing committee held on 23rd April 2014, Technical Publication 62,13 was released. The Technical Publication “Critical Evaluation of Stitched & Glued Manufacturing Joints” prepared by WICMA R & D Centre is an interesting and helpful publication to all members of FCBM and users of corrugated packaging. Congratulations to WICMA R & D Centre, headed by Mr. Pankaj Shah, Chairman WICMA R & D Centre and his team for their untiring efforts in bringing out this publication. In the Preface of this study Mr. Pankaj Shah has mentioned:
Announcement
WICMA Symposium WICMA will be organizing their Symposium on 12-13 September 2014 at Hotel Rama International, Aurangabad. For more info and participation details: Please contact WICMA office. Phone: +91 22 2850 0687 Fax: +91 22 2850 4523 e-mail: wicma@wicma.com; wicma@mtnl.net.in
www.wicma.com
‘The open question in the minds of users and manufacturers is which manufacturing joint sticked or glued performs better?’ ‘It is with the objective of establishing qualitatively and quantitatively the contribution of these manufacturing joints, towards the strength properties of boxes, this study has been conducted.’
‘It is hoped that this initiative of WICMA R & D Centre will be useful to corrugated box manufacturers, users and all others connected with corrugated packaging industry.’
OBITUARY We are deeply grieved to inform that Shri Pritambhai Parikh, passed away on 3rd April 2014. A very successful industrialist yet down to earth person, he was a man of meticulous details. A highly respected member of WICMA & FCBM because of his dedicated efforts for the betterment of Corrugated Packaging Industry in general. He had held important positions in both WICMA and FCBM. He had performed admirably as Hon. Secretary of WICMA from 1980-83. From 1983-89 he had served as the Vice-President WICMA and finally rose to the highest position in WICMA serving as President in the year 1989-90. Under his tenure as President, WICMA had hosted the 18th FCBM Conference at Lonawala, which was a grand success. He went on to serve as Hon Secretary FCBM in the period 1992-94. A self-made businessman, Pritambhai gradually built up his business empire from scratch. An honest human being, he was loved by one and all. He was a firm believer of social obligations and was always at the
forefront of charity for the cause of under privileged without any publicity. Soft spoken, hard working and most meticulous Pritambhai was sought after for advice at every event of WICMA and FCBM. His contribution to the growth, development and enviable unity of WICMA is well recognized and appreciated by everyone in the Association. In recognition of his selfless and meritorious services to the industry, WICMA had honoured him with Lifetime Achievement Award in 2013. We at WICMA pray to the Almighty for his soul to rest in peace.
The Corrugator | April – June 2014 | 45
46 | The Corrugator | April – June 2014
Kerala Corrugated Box Mfrs. Association holds AGM The 34th Annual General body meeting of the Kerala Corrugated Box Manufacturers Association was held on 29-3-2014 at 6.30 p.m. at Hotel Presidency, Ernakulam. While welcoming the members, President, Shri Xavier Jos expressed his happiness for the maximum co-operation that he is getting from all the members for the smooth functioning of the association.
He also stated that the Packaging industry is passing through a difficult period due to the general slackness, frequent price increase of all commodities and of course the economic recession. He continued to state that more attention is to be bestowed on indigenous market with new patterns and designs for packing materials. The conventional method of packing system is slowly changing to new methods and there are several new avenues where we have to make attempts, he added. President also mentioned that during the last FCBMI annual conference held at Chennai a team of 20 corrugators attended the conference. Hon. Gen. Secretary presented the annual report of the Association. Hon. Treasurer,
Mr.Bejoy Cyriac presented the audited accounts for the year 2012-13 and the same were adopted. During the meeting 13 new members were inducted. During open house discussion, FCBMI Vice President-II, Shri N.X.George made a brief on the present position of the corrugated industry and invited the members to present their opinion on the problems being faced by them. Mr. I. A. Peter, MC member mentioned that in order to improve the quality and production, the existing units have to upgrade with latest machineries and equipments. Mr.Ajaykumar, Chairman, membership development committee, mentioned about the problem of price increase of paper.
Association has to take some remedial measures to curb the situation, he added. There was also a general remark about the unhealthy competition between the corrugators which ultimately help the consumers and destroy the corrugators. Mr.N.X.George stated that in order to face the paper price increase problem, though we could make awareness among the consumers through newspaper coverage and appeals from the Association, each member should feel the importance of calculating the actual price structure and maintaining their prices based on the cost of paper and other raw materials. If all the corrugators stand united, we could convince the customers of our real problem. He also mentioned that instead of giving ads in news papers, proper news coverage will be more helpful. Mr.R.Suresh, Chairman, Conference 2015 spoke on the initial arrangements being made for the conduct of the incoming conference of the Federation. Mr. K. Krishnan, Managing Committee member, FCBMI offered vote of thanks. The meeting adjourned at 8.30 p.m. for family meet, introduction of sponsors, music, fellowship and dinner. A musical programme was performed by a professional troupe and some of the members also joined in the musical programme.
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48 | The Corrugator | April – June 2014
Visit to Interpack 2014 Interpack is the worlds largest Packaging Exhibition. In the recent years the presence of Indian Exhibitors as well as visitors has gone up remarkably, underlining the capabilities of the Indian Packaging Industry. Innovationparc Packaging is a unique trade name of interpack and the show’s own forum for special themes of the future. Visitors and exhibitors meet here for an exchange of creative ideas and the development of visionary ideas on basic social, economic and ecological themes.
Shri S. Balavassudevan, PresidentSicbma and a few Members from Sicbma Visited Interpack - 2014.
We are sure that Shri S. Balavassudevan would have been inspired by the Innovative Packages showcased at the Interpack - 2014. We do hope that “Bala” will now come up with even more interesting and innovative ways of using corrugated for his unusual creations - on the lines of what he created at the and for the FCBM Conference held in December at Chennai.
Survival Struggle
for Corrugated Packaging Units in North India due to Steep Increases in Paper Prices & other inputs Paper Mills in North India have increased prices of paper across all grades by Rs. 4 to 5 per kg. from the prices prevailing in January 2014. Shortage of local waste cuttings is driving its price to abnormally high level. This is the main reason cited by paper mills behind this price rise. To make matters worse paper mills are resorting to one week shutdown every month. At one end, box units are facing huge & frequent price hikes and at the other end the flow of supplies has been badly affected. Almost all conversion inputs have become dearer over past one year. Manpower costs have gone up almost by 40%. So has the cost of Power & Fuel. Other inputs also like starch, ink, wire etc. are lot higher. To compensate these hikes, minimum increase in Conversion Costs of Rs. 2000 pmt is needed. Freight costs also have shot up. Both incoming and outgoing materials attract much higher freight now & the same needs to be compensated also. Our esteemed clients are requested to appreciate the extremely difficult situation faced by the corrugated box makers and give appropriate increase in prices to help them serve better. Subhash Goel, President
Northern India Corrugated Box Manufacturers’ Association F-1, 2nd Floor, Shopping Complex, Mansarover Garden, New Delhi - 110 015. Tel.: 011-2510 3140 l E-mail: info@nicma.in
Northern India Corrugated Box Manufacturers’ Association released advertisement in leading financial daily in Delhi highlighting the “Survival Struggle” for Corrugated Packaging Units in North India due to Steep Increases in Paper Prices & other inputs
Announcement The 3rd Managing Committee Meeting of FCBM is scheduled to be held around 15 July. Details of the MC Meeting and Implications of the forthcoming Union Budget on our industry will be featured in July-Sept. issue.
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50 | The Corrugator | April – June 2014
Corrigendum In the Issue of The Corrugator Jan-March 2014 on page 61, the name of the speaker at the CorruPack Conclave 2014 held at Hyderabad, was wrongly mentioned as Anders Isaksson due to oversight. The speaker at the Conclave Mr. Mihir Shah, Aryan Paper Mills.
is
Mr. Mihir Shah has been well associated with the federation as a speaker at seminars and meets organised by FCBM and its regional associations. The inadvertent printing error is sincerely regretted. Mr. Mihir Shah, Aryan Paper Mills.
FCBM Publications P. No. Title of Publication 3:90 Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Bursting Strength of Corrugated fibre board. 4:90 Proceedings – Technical Sessions of Conference 1982 – 1990 6:91 Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Puncture Resistance of Corrugated fibre board. 7:91 Corrugated Box manufacturers’ Practical Standards – Nomenclature: A Glossary of Terms related to the Corrugated Packaging Industry 8:92 Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Water Absorption (COBB Method) 9:92 Technical Information Booklet – Variable Speed - Drives for Corrugated Machines 10:93 Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Grammage of kraft paper and Corrugated fibre board 11:94 Technical Information Booklet – Adhesives 12:94 Technical Information Booklet – Box Styles 14:96 Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Compression Strength of Corrugated Box 15:97 Corrugated Packaging Brochure 16:97 Technical Information Booklet – Industry Survey - 1996 17:97 Operational Manual ACS (ver 4.2) (Account Computing System) 18:98 Technical Information Booklet – Industry Survey - 1997 19:98 Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Ring Crush resistance of Paper and paper board.
20:99 Technical Information Booklet - Industry Survey – 1998
34:06 Proceedings – Technical Sessions of 34th Conference 2005, Bangalore
21:99 Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Moisture Content in Paper and paper board.
35:06 Technical Information Booklet – Industry Survey – 2005
22:00 Technical Information Booklet – Industry Survey – 1999
37:06 Technical Information Booklet – International Rules for Corrugated Board and Cases
R-1:00 Corrugated Box manufacturers’ Practical Standards – Box Dimensions, styles, Mfrs. Joints 23:02 Technical Information Booklet – Industry Survey – 2001 24:02 Project Report (Full Version)
i) A study on the Important Properties of Kraft paper at Different Climatic Conditions
ii) A study on the influence of Properties of Kraft paper on the Properties of Corrugated Board and Box at various climatic conditions
36:06 Technical Information Booklet – Units of Measurement and Conversion Factor
38:07 Proceedings – Technical Sessions of 35th Conference 2006 39:07 Technical Information Booklet – Restricted Heavy Metals Specification in packaging Material 40:07 Technical Information Booklet – Guidelines for Designing Heat Transfer System using Heat Transfer Fluids 41:08 Proceedings – Technical Sessions of 36th Conference 2007
25:02 Project Report (Condensed Version)
42:10 Proceedings – Technical Sessions of 38th Conference 2009
26:03 Technical Information Booklet – Industry Survey – 2002
43:11 Proceedings – Technical Sessions of 39th Conference 2010 – Interactive DVD
27:03 Proceedings – Technical Sessions of 31st Conference 2002, Mumbai
44:11 Technical Information Booklet – Industry Survey – 2010
28:03 Proceedings – Technical Sessions of 30th Conference 2001, Chennai
45:12 Proceedings – Technical Sessions of 40th Conference 2011 – Interactive DVD
29:04 Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Thickness of Board
46:12 Scoring allowances and Blank size 47:13 FCBM Members’ Directory 2013
30:04 Technical Information Booklet – Industry Survey – 2003 31:05 Proceedings – Technical Sessions of 32nd Conference 2003 32:05 Proceedings – Technical Sessions of 33rd Conference 2004 33:05 Technical Information Booklet – Industry Survey – 2004
Fede ra Box M tion of ANUF ACTURERCorrugate d S of India
Mem Direc bers’ tory 2013
For further details contact:
Federation of corrugated box mfrs. of India Tel.: +91 22 2850 0687, E-mail: adminfcbm.org, www.fcbm.org
The Corrugator | April – June 2014 | 51
The Widest Range of Testing Equipments, Saurashtra – a trusted name in Testing Equipments
Box Compression Strength Testers
Pioneers in the development of testing equipments, Saurashtra has etched for itself a premier position in the field of testing of packaging materials and packages. Since over 25 years, Saurashtra continues to enjoy the trust and confidence of manufacturers and users of packagings as well as leading institutes and laboratories. Today there are over 7000 satisfied customers in India and abroad using equipments of Saurashtra. With a wide range of equipments for scientific and accurate testing of paper, paperboard, corrugated boards & boxes, Saurashtra stands out as a single window for testing equipments - ably supported by technical backup and prompt service. Now, Saurashtra also offers equipments for testing plastics and other packaging materials as well as engineering and automobile industry.
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Other Equipments available l Specimen Cutter for GSM, Ring Crush & Edge
Crush Tests l Specimen Maker (Fluter) for Concora Medium Test l Dart Impact Tester l Torque Tester l Air Permeability Tester All Digital Models are also available with Integrated Computerised Touch Screen Control Panel
52 | The Corrugator | April – June 2014
Measures ability of the container to resist external compression loads during transit and storage. The ultimate test for determining overall quality and performance of the packages.
Available in: UBC1M/1T - Digital Model UBC1M/1T-P - Microprocessor based Digital Model UBC1M/1T-TS - Fully automatic with computerised touch screen control panel Model
Bursting Strength Testers Available: 2-in-1 Type, Paper Tester & Board Tester in Various models like Dual Pressure gauge model, Digital economy model Fully Automatic Digital Model, Fully Automatic Microprocessor based Digital Model, Fully Automatic with computerised touch screen control panel.
Two-in-One Digital Economy Model Paper & Board Tester l Two Diaphragm Seats l Digital Indication of readings l Peak Hold facility l Manual Clamping
Crush Tester Useful for determining Edge Crush, Flat Crush, Pin (Ply) Adhesion of Corrugated Board and Ring Crush and CMT of Paper and Paperboard. Available in: UCR - Digital Model, UCR-P Microprocessor based Digital Model UCR-TS Fully automatic with computerised touch screen control panel.
Conforming to National and International Standards Puncture Resistance Tester
COBB Tester
Gives reliable indication to evaluate fabrication factors along with material values in a composite fashion.
Substance Indicator
Determines water absorption/ penetration (cobb value) of paper and paperboard as specified in standards.
Available in: UPR - Analogue Type UCR - DIGITAL Microprocessor based Digital Model
Measures directly substance of paper, paperboard and other materials in terms of G.S.M.
Model: UCOB
Internal Ply Bond Tester
Caliper Thickness Gauge
Sample Cutter
Measures Caliper thickness of variety of materials. Available: UCTG01 & UCTG01-D With 10mm capacity and least count of 0.01 mm UCTG001 & UCTG001-D With 1mm capacity and least count of 0.001 mm UCTG002-D With 20mm capacity and least count of 0.001 mm
To Determine the Internal Bond Strength of Paper, Board and Laminates Model: UIBST Microprocessor based Digital Model supplied with Sample Preparation Station as per the standards.
Introducing
Model: USC for preparing various paper samples for GSM, RCT etc...
PAPER MOISTURE INDICATOR
Features Pre-set Material Modes
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Paper (4.7- 18.2%) Arbitrary (8 - 100%) Baled scrap paper (6-40%)
l
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l
Hand held equipment
l
Direct Instant reading
l
Back Lit 2 line LCD Display.
S S
View Saved Reading S Total Reading S Min Reading S Max Reading S Average reading With Attachments can be used for Waste Paper Total Memory of 300 readings (100 readings in each mode) Low battery Indicator Buzzer sound to alert for out of range readings
Model: U2100
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SAURASHTRA SYSTOPACK PVT. LTD. 102 & 104, Shilpin Centre, 40, G. D. Ambekar Road, Wadala, Mumbai - 400 031, India. Phone: +91 22 6736 4343 ● Fax: +91 22 6736 4300 ● E-mail: info@saurashtra.net ● www.saurashtra.net
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54 | The Corrugator | April – June 2014
Corrugated Liner Problems Question We’re cutting corrugated paper, single wall, using soft anvil rotary steel rule diecutting. We have had this problem intermittently but it is becoming more common as of late. The inside liner tears in a sporadic pattern when diecut, running across the flutes. The tears in Diagrams 1 and 2 [All Diagrams next page] run pretty much parallel with the scores but we’ve had them running diagonally as well. Diagram 3 is an image of the cutting die. The diemaker suggested Kushion Krease rubber along the scores to crush the board more, but this has had limited success in other dies for which we have had the same issue. Is this entirely a board issue and is there anything else we can do to eliminate this problem? TechTeamTM answer The fracturing is being caused by the paper being stretched beyond its elasticity. This can happen during cutting or creasing. As the metal is pushed into the fluted material, the inner liner tears before the flute is crushed because the medium is stronger than the liner. The best way to solve this issue is to crush the area next to the cut or crease. The diemaker who suggested a Kushion Krease type product is on the right track. You do want to ensure the Kushion Krease is about 1/32” (.793mm) below the crease. If the Kushion Krease is taller than that, the score will roll, if it is lower, the paper will most likely fracture. Another suggestion is to widen the crease from a 4 point to a 6 point or an 8 point. The wider crease will not puncture the inner liners as easily as the 4 point. The real issue is to clamp the flueted material down before the metal rule begins to compress it. This distributes the stretch of the paper over a la rager area in stead of a small area. This clamping is done by using more rubber or Kushion Krease.
Addition Comments I should have added that this is the first time we had this issue where the scores go
Clint Medlock “Stafford Cutting Dies, North Carolina”
across the flutes. This board also had issues of the liner cracking on the opposite side. The commonality I see is that it involves the scores that run in the through press direction. So is your recommendation to make all scores, whether with or across corrugation, 6 or 8 pt with Kushion Krease? So far we’ve only had this issue on single wall. For double wall the scores are already 8 pt, but you would recommend Kushion Krease for it also? Is there a rubber hardness that you would recommend aside from the Kushion Krease for the clamping and how would you go about clamping the material prior to cutting/creasing? Finally, Diagrams 4 – 6 show how the cracking progressed on the opposite side. It starts just after the fold-in flap and works its way down and the corrugated substrate appears pushed in between the creases. This occurred about every 100 sheets and lasted for about 20 sheets before starting the cycle again.
the feed direction. If you are soft feeding (cross corrugation) the sheets, the crease heights can be the same height, but the horizontal height must be lowered from normal. Diemakers use different cut and crease heights, so this example is what I would use, but not necessarily what your diemaker would select. The important thing is the difference in the heights from cut to crease.
Additional answer
If you are feeding the sheets across the flutes (soft feed), for diecutting 32 ECT C-Flute, I would suggest a cut height of .970 (24.6mm) curved cut and 1.000” (25.4mm) horizontal cut. I would suggest a vertical crease height of .860” (21.8mm) and a horizontal crease height of .860” (21.8mm). I would use a .315” (8.00mm) high Kushion Krease (using 1/2” dieboard) on the
There are many things that can cause the fracturing. First, the fracturing can be caused by the crease being too tall. The crease height will be different depending on which direction the flutes travel through the press. Normally the vertical crease height is a bit lower going through the press for flutes running in
If you are feeding the sheets with the flutes (normal feed direction), for diecutting 32 ECT C-Flute, I would suggest a cut height of .970” (24.6mm) curved cut and .990 (25.14mm) horizontal cut. I would suggest a vertical crease height of .860” (21.8mm) and a horizontal crease height of .880” (22.3mm). I would use a .315” (8.00mm) high Kushion Krease (using 1/2” dieboard) on the vertical crease with no additional crush next to the crease.
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Diagram -1
Diagram - 4
Diagram - 5
Diagram -2
Diagram - 3
Diagram - 6
horizontal crease with no additional crush next to the crease. If you need additional crush next to the Kushion Krease, you will want to use the same hardness as the cushion crease. This is usually the same as the rubber used in small slots.
to right. This keeps you from wearing a groove in one area. When I see fracturing happening on a set number of impressions or time intervals. I generally suspect a bad spot in the anvils. The only correction for this is to trim the anvils or rotate them. Sometimes rotating only moves the problem to another area. We hope this helps your process.
If the fracturing continued, first I would check the back of the die to make sure that the crease rule is seated properly. if it is not flush with the back of the wood, it may be higher than necessary, thus the cause of the fracturing. If the rule is seated, I would suggest going to either a 6 point or 8 point crease. If the fracturing only occurred occasionally, I would take a look at the anvils. The fracturing may be caused by a high spot in your anvil. As you are diecutting, your anvil oscillates left to right and how often it returns to the same spot depends on the spped of your machine. The oscillation on most machines is about 3/4” (19.05mm) left
The topic was answered by TechTeain member Clint Medlock (Stafford Cutting Dies, www.gostafford.com) and edited by Joe Adkison (Adko, Inc., www .goadko. com). You may contact Clint at 1-704821-6330 or email him at clintm@ gostafford.com. You may contact Joe at 1479-646-2533 or email him at joe@ goadko.com. For more information on the IADD Tech Team, visit the IADD’s website at www.iadd.org.
This article is reprinted with permission from the International Association of Diecutting and Diemaking’s monthly magazine, The Cutting Edge. The ADD is an international trade association serving diecutters, diemakers and industry suppliers worldwide. IADD provides conferences, educational and training programs, a monthly magazine, online resource library of 450 + technical articles, industry experts to answer technical questions, publications and training manuals, recommended specifications, online used equipment marketplace, videos and more. IADD also co-presents Odyssey, a bi-annual trade show and innovative concept in technical training featuring a hands-on Techshop where training programs come alive in an actual working diemaking and diecutting facility inside the exhibit are. Visit www.iadd.org or call 1-815-455-7519 for more information about IADD.
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Automatic Case Erecting Standards and tolerances for Corrugated Cartons Compiled by: Sateesh S. Mehta Anu Enterprises, Mumbai
Regular Slotted Containers (RSC) are the commonest type of corrugated boxes and they lend themselves readily to automatic case erection. Standards for corrugated boxes, as regards bursting strength, compressive strength, moisture content, etc are already laid down. However, for automatic case erection, some additional parameters need to be standardized to ensure that
Minor Flap (Top)
3. Filled boxes will stack squarely during palletization, storage and shipment. The following standards are developed on the basis of our experience, in order to enhance the understanding among manufacturers of corrugated boxes, packaging machinery and the final users of the boxes. The standards are in the form of guidelines and are not intended to supersede or modify any existing standards laid down by competent authorities.
Definitions Regular Slotted Containers (RSCs): A box style manufactured from a single sheet of corrugated board. The sheet is scored and slotted to permit folding. Flaps extending above and below the panels form the top and bottom of the box. All flaps are of the same size from the edge of the sheet to the flap score lines. The two outer flaps (major flaps), after adjusting scoring allowance are half the width of the container, so that they meet at the centre of the box when folded.
Horizontal Score Lines Major Panel
Manufacturer’s Joint Minor Flap (Bottom)
Major Panel (Bottom)
Slot
1. The packaging is usable and can fulfill its intended function 2. Knocked down boxes (K. D. Blanks) will run smoothly on automatic erectors, fillers and closing equipment and can be easily erected by machines as well as by hand.
Major Panel (Top)
Fig. 1 - K. D. Blank
Configuration:
Manufacturer’s Joint:
A flat, unopened box is called a K. D. Blank. It is designated ‘Right Hand’ when the longer panel appears on the right or ‘Left Hand’ when the longer panel appears on the left side.
A joint or seal made by the box manufacturer to join the ends of the corrugated sheet. A narrow tab extends from the end of the panel to overlap the side panel. It is fastened with adhesive or wire staples. KD Blanks delivered to the customer’s plant should have the Manufacturer’s Joint in the middle of the Blank.
‘A’
Flutes:
‘A’ ABC Chemicals paints LTD
TYPICAL RIGHT HAND CASE Major Panel must be on RIGHT side in upright position
ABC Chemicals paints LTD
Flute directions are usually perpendicular to the base of the box for top opening RSCs and parallel to the base of the box for endopening RSCs.
Dimensions: For the purpose of automatic case erecting, filling and palletizing equipment, the outside dimensions of the finished box
H
TYPICAL lef t HAND CASE Major Panel must be on lef t side in upright position
Fig. 2 - Configuration
W
L
Fig. 3 Dimensions of Finished Box Cont. on Page 63 The Corrugator | April – June 2014 | 59
New
Fingerless Double Profile Single Facer Superior Technical Features l Design Speed: 70Mt/Min. l Available Sizes: 12” [300 mm ] AND 14” [350mm] l Vacuum Suction Fingerless Design driven by heavy duty blower provides perfect flute formation l Pressure Roll Dia: 305mm. l Twin Flute Structure: One Flute Unit working and another ready for immediate order change. l Heavy Duty Quick Roll Change Cassette System controlled by Hydraulic System for change of flute rolls. l Corrugated Rolls Made of Special Alloy Steel. l Built in Pre heating & Pre-conditioning Rollers ensures absolutely secure bonding. l Heavy duty Hydraulic Power pack. l Gum Circulating System. l A. C. Drive for speed control. l Available Width: 1200-2200mm. l Flute Profiles: A,B,C,E, or as per requirement.
Shearline Machines Pvt. Ltd. 60 | The Corrugator | April – June 2014
B-6, Rupal, Shivaji Chowk, Daftary Road, Malad - East, Mumbai-400097. India Tel:- +91 9821 031103 / 98210 54833 E-Mail: corporate@shearline.in l www.corrugatedbox.com
Machines that make better boxes from DOSHI Super Shear Line is dedicated to the d evelop ment and manufacture of innovative machines for the corrugated packaging industry. In keeping with the trend of the industry which is swiftly switching to Automatic Process – we have developed complete In-line Corrugators, ranging from- 32” 3ply Eflute Plant to 80” 5ply Plant with Numerical Control System
3-Colour Flexo Printer
Flat Bed Die Cutter Hydraulic Waste Baling Machine
lants d P 4 2 le Over y instal d alrea In-line Automatic Corrugating Board Plant
SUPER SHEAR LINE
B/ 305, Rupal, Shivaji Chowk, Daftari Road, Malad (East), Mumbai- 400 097. E-mail: info@shearline.in l www.corrugatedbox.com l www.shearline.in
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Prime Wires Pvt. Ltd.
Prime Wires Pvt. Ltd. Plot No, 89, Survey No. 66, Opp. Jay Equipment Pvt. Ltd. Near Sunita Dies, Waliv Phata, Sativali Road, Vasai(East), Dist.Thane - 401208 Email: seemastitch@yahoo.co.in | www.jyotistitchingwires.com
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Cont. from Page 59 are considered. Dimensions are given in the sequence of Length X Width X Depth (or Height). Length is always the larger of the two base dimensions, Width is the smaller dimension and Height is the dimension perpendicular to the Length and Width. End-opening RSCs are measured as though they were top opening.
Max. 4mm cm
5
10
15
K. D. Blank
Ragged Edge
The KD blanks upon delivery to the customer’s plant and during storage in the customer’s plant should be flat and its corners and edges should not be damaged or bent. Flatness of the KD Blank shall be measured by placing the Blank on a flat surface or floor and the maximum variation shall be measured. The Blank should be in contact
Unwanted extra vertical crease
Inadequate width of slot
ABC Chemicals Paints Ltd.
Edge Damaged or Bent
2. Warp The amount of warp of the KD Blank upon delivery to the customer’s plant shall not exceed 4 mm for 30 cm of measurement. Warp shall be measured by placing a 30 cm straight edge ruler against the most concave surface of the Blank. The distance from the ruler to the concave surface shall then be measured.
30
Fig. 4 - Measurement of Warp
1. Dimensions l Panels: Variations
25
WAPP MEASUREMENT
TOLERANCES in the dimensions of the panels shall not exceed 1.5 mm for each panel and variation in the overall dimensions shall not exceed 3 mm. Variation in the dimensions of the two diagonals shall not exceed 3 mm. l Slots: The purpose of the Slot is to facilitate folding of the flaps at the score lines without interference of the other flaps. For this purpose, the width of each minor flap shall be less than the inside dimension of the box. The width of the Slot shall be 6 to 8 mm and the Slot shall be centered around the vertical score line. l Manufacturer’s Joint shall be parallel to the vertical score lines of the box. Variation shall be within 2 mm.
20
Slot is not creased around the vertical score line Fig. 5 Common Defects In Blanks
with the flat surface throughout its length and breadth.
2. Scores The vertical and horizontal score lines shall be sufficiently deep to enable opening of the Blank and folding of the flaps easily and without the use of excessive force. There should be no unwanted score lines on the Blank.
3. Flap Gap The major flaps of a closed box should not overlap each other and the gap between these flaps should not exceed the thickness of the corrugated board.
We are of the opinion that boxes that do not exceed the above tolerances will run satisfactorily through automatic case erecting, filling and palletizing equipment and we believe that corrugated box manufacturers are capable of manufacturing boxes within these tolerances commercially in their existing plants. Courtesy : Reprinted with permission from Industry Insight – A Technical Bulletin of the Corrugated Industry by House of WICMA
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www.insunco.com
: +91 98849 50600
Mobile
Wire Holder
email : insun@insunco.com
Strapping
Address : PlOT NO. 26, MeTHA NAGAR, M.M.C. POST, CHeNNAI - 600 051.
India Office
Stitcher
Tel : +82 32 564 5013 fax : +82 31 997 5014
64, Hwanggeum 2-Ro, Yangchon-eup, Gimpo-City, Gyeonggi-Do, Korea 415-843
InSun Co., Ltd.
Manufactured by
Counter Ejector
Sheet Thickness
Main Power
Max. Stitching Speed
15 Kw
85 Sheets/Min
180 M/Min
3,100 x 13,000 mm
300 x 900 mm
ES-32
3,500 x 13,000 mm
300 x 900 mm
1,200 x 2,900 mm
Corrugated Board 3 – 10 mm
2,800 x 12,000 mm
M/C Dimension Max. Belt Speed
300 x 900 mm
1,000 x 2,200 mm
ES-28 1,200 x 2,500 mm
Specifications ES - 25 Min. Sheet Size
Max. Sheet Size
Model No.
AUTO FOLDER GLUER + DOUBLE STITCHER + COUNTER EJECTOR + BUNDLER
Honeycomb Paper Opens up a new era in Panel-Type furniture. Honeycomb paper is a new type of sandwich structure, energy saving material made according to the honeycomb found in nature. The corrugating medium is glued into innumerable hollow threedimensional regular hexagons to form a whole load-carrying paper core, and surface paper is pasted onto both sides. Because it is lightweight, inexpensive, strong and recyclable, honeycomb cardboard is popular, especially in developed countries like the Netherlands, the US and Japan. It is a new type of green packaging that can save resources and protect the environment. At various domestic furniture exhibitions this year, honeycomb paper furniture will be under the spotlight, thanks to the features just listed. China’s annual wood consumption is 50 60 million m3. According to the National Energy Saving and Emission Reduction Manual issued by the Ministry of Science and Technology, saving 1m3 wood can reduce carbon emissions by 643g. If 20% of China’s total wood consumption in furniture manufacturing is substituted by honeycomb paper core, the country can cut carbon emissions by about 154.3 million tons a year. By widely promoting the use of honeycomb cardboard parts for furniture in furniture manufacturing , we can save about 10 million m3 of wood a year.
expended consumer good. Annual wood consumption is 50-60 million m3 a year and continues to grow rapidly. This is putting great pressure on the implementation of the sustainable development of China. To ease the increasingly prominent contradiction between market supply and consumer demand, paper honeycomb furniture emerged at the right time.
Paper Furniture Breaks Market Trends and Brings New Development Opportunities During the three decades since China’s policy of reform and opening up began, real estate and furniture manufacturing have flourished, thanks to a large number of wood-based panels. There were over 50,000 furniture factories in China with a sales volume of over RMB 1.01 trillion (USD 164.1 billion) in 2012. After cars, clothing and household appliances, furniture is now the fourth most voraciously
Under the dual influence of the need to be environmentally sensitive and compliant with national regulations, honeycomb paper furniture is becoming increasingly popular. Wood consumption by the furniture industry is up to 80 million m3 a year in China. If honeycomb composite board is widely used in furniture manufacturing, it will greatly reduce wood consumption. Experts predict that the use
of one ton of paper honeycomb composite materials will save 30-50 m3 wood. Take a 20mm thick plate for example. If honeycomb composite board is made of medium density fiberboard 2.5 mm thick, the volume and weight of material is only about a quarter of the solid medium density fiberboard, while the cost of the composite board is only about half of the solid board and the composite board has advantages such as lightness of weight, hardness to deform and ease of transport. In the near future, paper honeycomb certainly has the potential to tower over rivals in the furniture market, based on its unique advantages. Currently, in Guangdong alone, there are over 200 furniture companies using honeycomb paper core. Many locally renowned furniture companies like Idea & Design, Dickson, Haworth, Hormann, Wanlibao, Royal, Fuwei, Hing Lee Furniture, Goldfine, Tiancheng, New Lantian, Zhejiang FDD and Sichuan QuanU have made at least part of their furniture parts using honeycomb paper. Others include some Ikea OEM factories.
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In Hong Kong, high-class furniture made of high-grade boards composited by highquality honeycomb materials – called “Aircraft Wood” - is very popular. In Japan, housewives prefer light honeycomb furniture, as do many Japanese businessmen. But compared with the rest of the furniture industry, companies using honeycomb paper to produce furniture are still a minority. Therefore, there is still a large market waiting to be developed.
Green Design Supports EcoAwareness in the Home Today, to facilitate the trend towards environment friendly living spaces, the “greening” of furniture materials has become key. To support environment friendliness, Sitrust vigorously promotes honeycomb paper furniture. Honeycomb
p a p e r technology is more widely used outside China, especially for furniture. F o r e i g n designers and companies, who attach great importance to environmental protection of furniture, praise this new material highly. Some products of popular mainstream companies like IKEA use honeycomb board technology. In recent years, honeycomb paper furniture has won high praise from environmentalists because of its eco-friendly benefits. The design and application of honeycomb paper furniture fully comply with green design thinking. Green design considers the influence on the environment from design to material selection, product structural functions, production methods, packaging and transportation and product usage - even to the processing of disposed products. Green design has ten basic principles that align with modern design: healthy and complete design; easy to use; parts easily replaceable and able to be used repeatedly; compact and easy to cleaned; easy to separate and combine; easily recyclable, low pollution and low energy consumption; elegant and suitable for production environment; materials easy to source; low consumption and holistic design principles. The design and production of paper honeycomb furniture fully comply with green design thinking. Since 2000, with further implementation of the national forests and environmental protection policies, as well as the improvement of people’s living standards, consumers are
more demanding in terms of wanting products with a good environmental performance. The prospect for honeycomb paper furniture are immeasurable.
Pioneering Industry Innovation, At the Forefront of Mainstream Production After World War II, Western European countries wanted to ease the shortage of resources, due to the large-scale reconstruction of homes. From this need honeycomb paper technology emerged. Because of environmental protection and energy saving, low carbon emissions and because it has no disadvantages from using wood or carrying biological pathogens, honeycomb paper furniture is suitable for export. High profile local and international furniture manufacturers like IKEA, Red Apple, FZD, Goldfine, QuanU and Kinwai are adopting this technology. In keeping with global energy saving, environment friendly, sustainable development trends, paper material is made according to the honeycomb structure principles. Body paper is glued on to hollow three-dimensional hexagons. In this way, a whole piece of paper core carrying load can be formed. Furniture made from honeycomb paper has excellent load-bearing soundproofing capacity. Using honeycomb cardboard as internal filling material is a major feature of paper furniture. This production method not only saves boards, but also reduces the weight of furniture, and it is easier to shape and transport. After technical improvements and upgrades, this kind of honeycomb paper that is used as furniture internal filling materials has strong supporting capacity and high durability. Thus, honeycomb paper furniture becomes key in the mainstream market, thanks to industry innovation. Experts have pointed out that honeycomb cardboard is more suitable for making thick board furniture such as counter tops and bookcases, which not only can save 10% -15% of the cost, but also solve the problems that the thick board is difficult to be shaped and transported. In addition, paper can be recycled 15 to Cont. on Page 71 The Corrugator | April – June 2014 | 67
Phone : +91 183 2583636, 2589845. Mobile : +91 99881 01838, 98158 04604 +91 95923 63636, 92573 63636 E-Mail : sondexim@jla.vsnl.net.in sondexim@gmail.com support@sondengg.com 70 | The Corrugator | April – June 2014
Cont. from Page 67 17 times, to some extent, this solves the problem of having to recycle old furniture. China has the largest volume of fast-growing wood in the world. However, because of its low density and short fiber length, this kind of wood is only suitable for making paper or paper-plate-type manmade boards, not the load-bearing parts of furniture. Most wood used to make the load-bearing parts of furniture is imported. The promotion of paper furniture can greatly reduce the use of wood. For example, 1m3 honeycomb board can stretch to 20-50 m3. According to industry statistics, the 2013 sales volume in China’s furniture market was about RMB 1.01 trillion (USD 164.1 billion). Of this, pure plate-type furniture (excluding the type that combines plate and wood) accounted for about 40%, equal to RMB 400 billion (USD 65.1 million). In theory, all plate-type furniture is compatible with honeycomb cardboard. Although at present, honeycomb paperboard furniture accounts for far less than 1% in the plate-type furniture market, a symbol of how unpredictable the broad prospects remain.
Honeycomb Paper Industry Development Summit In order to further promote the use of honeycomb paper in furniture, Reed Exhibitions held a “Honeycomb Paper Industry Development Summit” during SinoCorrugated South 2014 on April 10 and 11. The Summit featured the latest information on the development of honeycomb paper, locally and internationally, including an analysis of the best production, application and innovation solutions. It also gave honeycomb paper industry professionals valuable information, the chance to strengthen their network of connections and new development opportunities in segments like technology, production and sales. As the social economy develops, and to meet the requirements to balance supply and demand, the development prospect of paper honeycomb furniture face dazzlingly bright growth prospects. Throughout opportunities and challenges, the paper honeycomb furniture will become a market leader, ushering in a new era for fast indoor furniture. We look forward to it with relish. Source: www.reedexpo.com.cn
Bombay Packaging Corporation, headed Mr. Kirit Doshi Past President FCBM specialiseres in Honeycomb Products. Packraft at Faridabad also specialises in Honeycomb products. There are some other corrugated packaging manufacturers, who have pioneered honeycomb product. Some of The Honeycomb Products of his companies are featured here.
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Packaging Gaining a foothold, overcoming maladies The $24.6 bn worth Indian packaging industry has 22,000 firms comprising of raw material manufacturers, machinery suppliers,ancillary material of which 85% units are MSMEs. India is at the threshold of explosive growth:’
Today, India is the sixth largest packaging market worldwide. It is expected to grow at 12.3% CAGR during next 4-5 years to become fourth largest global market, with sales of $42.7bn.
Pira anticipates that food packaging consumption will steadily increase by 8.2 % on average, annually between 2011 and 2016, amounting to around Rs 294.14 billion by 2016.
According to Pira, packaging sales in India were valued at Rs 672.4 billion ($13.9 billion) in 2010, representing an increase of 14.4% on 2009 levels after a sales increase of 8.6% between 2008 and 2009.
Demand for drinks packaging is expected to improve at a rate of 8.2 % per year on average to 2016, reaching a total of Rs 99.40 billion.
Board packaging sales are projected to grow at an annual average rate of 7.9% in 2011-16 to Rs 269.40 billion. Rigid plastic packaging sales are projected to grow on average by 16.1% between 2011 and 2016 to Rs 292.91 billion. Flexible plastic packaging sales are projected to grow on average by 10.2% per annum in the period to 2016 to reach Rs 311.42 billion. Across other areas, between 2011 and 2016 Pira forecasts average 8.0% growth in foil packaging, 74% growth for paper packaging, 6.2% growth in metal packaging sales, 8.3% growth for glass, and 3.9% growth across other packaging sales.
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Health care packaging demand is projected to grow at an annual rate of 8.9 %, reaching a value of Rs 23.68 billion by 2016. Consumption of other packaging is expected to progress on average by 8.5% per annum, attaining a value of about Rs 547.57 billion by 2016.
Packaging in India A snapshot The paperboard packaging market is growing. In India, there’s a 1:1 correspondence between the GDP and the packaging market growth. But the top-end, the ones with value-added board has been growing at the rate similar to the top-line consumer segment, and that has been reporting a 15-20% growth. Folding cartons will see-an average annual growth rate of .9% in BRIC (Brazil, Russia,India, China) between 2010 and 2016. The recent report estimates that the folding carton demand in India is predicted to increase by almost 1.8 million tonnes from 2010 to reach a total of 3.8 million tonnes by 2016.
Today, flexible packaging in India including flexible plastic, flexible aluminium/paper, flexible paper, and flexible aluminium/ plastic accounts for 65% of all packaging forms. The trends suggest that consumers opt for large sized packages; also, the small sized packages are seeing a lot of action. The easy-to-open packages like pumps or sprays are becoming popular especially in beauty and personal care products. It’s interesting to note that Indian mLLDPE demand is estimated at 70 KTPA (kilo-tonnes per annum) in 2010 and will exceed 200 KTPAby 2020. Target markets are dairy products, edible oil, food, detergents, and cosmetics. India has 600-800 flexible packaging converters. Most can produce less than 250 tonnes per year but at least ten can produce more than 4,000 tonnes per year. The per capita consumption of packaging in India is meiely4.3 kg per person per annum, as against Germany’s 42 kg and Taiwan’s 20 kg, which is very low compared to global standards. The sector-wise break-up of packaging industry in India can be given as follows: processed food packaging is 48%; personal care packaging is 27%; pharma is 6%; and rest is 19%. The food packaging sector grows in tandem with food processing industry, which is surging at 6-7%. This is higher as compared to 4% growth in agriculture sector. The plastic packaging is growing at 20-25%, rigid containers at 15%, PET bottles at 25% and tubes at 10-12%. The total flexible packaging market is $671mn. The domestic demand for paper is 7.6 million tonnes, which is 40% of the total production that goes into packaging.
CORRUGATION The Indian kraft market market is approximately four million tonnes (Crisil estimate: 3 5.million million tonnes), which is growing at 7% to 8%. The corrugated box industry in India is fragmented says WICMA. There are more than io,000 units with estimated market value at Rs 10,000 crore. The automatic corrugated board making machines are pegged at 250 but operating at70% capacity. The corrugated industry growth is 12% to 15%. As of 2013 India represents 3.1% of world’s corrugated market share standing at number five and producing 6,326 mn sq/ rn board. The expected growth forecast of corrugated production for 2011-2016, in India is 8.8% per year. Corrugated board printing is mainly by sheetfed offset and flexo. Many of India’s corrugators have increasingly adopted flexo printing with water-based inks. Four trends in corrugation The first trend is the importance of an automated packing line and high-end converting equipment. The second trend, has been the boost to the fruits and vegetables segment; and multi colour top quality graphics.
The third trend was the entry of modern retail and therefore colour and photorealistic images. The fourth trend is the entry of modern retail and the new possibilities for printing on the brown outer surfaces. The advent of international groups in the corrugated converting segment meant further development of the Indian corrugation industry and that the local corrugators have to tighten their belt to be prepared. This would raise the quality bar. And finally, customers are seeking lightweight boxes with the highest quality at attractive prices for the growing market for large-sized packages and logistic display.
(Source: S. Venkatraman, Presentation at Corru pack 2013) Source: PrintWeek India Survey Print in 2014 PrintWeek India,10 May, 2014 Vol. VII. Issue 1. We gratefully acknowledge sincere thanks to Mr. Ramu Ramanathan, the Editor of Print Week India for permitting us to reprint this sourvey.
The Readers are requested to send their corrected & complete addresses to ensure that they receive their copy of “The Corrugator” without fail
The Corrugator | April – June 2014 | 73
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Spot Waste and Eliminate!
Dr. Ipshita Basu Guha Associate Editor, SME WORLD
When I was doing my doctorate, I came across many accomplished people linked to the power sector in various capacities. They all were kind enough to spare time and share their insight with me, answer my questions and educate me far beyond the knowledge that I was seeking. They all shared a common view about the transmission and distribution loss (~30%). It was pointed that if we simply reduce the losses, we will have lot more extra power to bridge the demand and supply gap instead of trying to continuously add generation capacity to cover the deficit. Can you imagine the colossal amount of waste of precious resources like coal and gas? There are many combined cycle power plants today which generate power using gas as well as steam. The steam turbines are run by converting the heat generated while running the gas turbines using a heat recovery steam generator which otherwise would go waste. However, this article is not about power generation plants; it is about waste in corrugation business, how it gets created, what its effects are and how can we minimize it. Corrugation business is a highly resource intensive trade where the margins are dwindling as days go by. On one hand creditors have to be paid on time preferably within 30 days
(in case of small manufacturers a 60 days credit period would incur higher rates) while debtors are more relaxed towards their outstanding bills. Though packaging holds a pivotal position in today’s supply chain and logistics scenario, packaging suppliers do not figure on top of the payables’ list in majority of the companies with raw material suppliers finding preference and priority.
Uneven Distribution of Load There will be inevitable build up of inventory at that stage and throughput will be less. The waiting of parts to get processed is also a waste of resources. Suppose the stitching section of the carton manufacturing process has only two machines with limited manpower to operate them at the same time, there is bound to be inventory build-up at the beginning of this process. It will be immaterial if the corrugation, pasting, slotting and scoring sections are giving uniform and steady output. The productivity of the entire plant will get reduced as the stitching function is unable to give the same even output.
We will try to understand the 3Ms – Mura, Muri and Muda as identified by the Toyota Production System (TPS) that has propagated Lean Manufacturing and try to understand them in the context of corrugation plants.
Unevenness and Strain The first sign of problem is irregularity or unevenness in any process. This is Mura. If the production system is not leveled properly then certain parts will have more work than others.
Strain on One Vehicle and Less Load on Another With unevenness, comes overburden or strain. This is known as Muri under TPS. Look at your own body. If you are reading for a very long time, your eyes start watering or paining. The rest of the body is fine. But due to strain Cont. on Page 79 The Corrugator | April – June 2014 | 75
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Cont. from Page 75 on your eyes you are unable to do anything else till you rest for a while. Similarly, in factories there is strain on machines and manpower. This diminishes the efficiency of that particular process. There can be issues of quality and chances of defects in the output. In our day to day business, we try to strike a fine balance of quality, productivity, on-time delivery while maintaining safety of the premises and staff.
and decide to use. You will be wasting the width of 1.50 inches as your customer will not be keen to pay for the extra paper. Liberally viewing, most support functions seem non-value adding for a customer. However, we cannot do away with administrative or IT support activities in a company. The objective should be to rationalize such processes and restrict waste generation.
Imagine a case of uneven production where workers have to keep changing the reels and moving them back and forth the storage area and corrugation machine. How much time and resources are being wasted because of the same? Is your customer paying for these costs? No! Waste is nothing but consumption/ utilization of resources which provides no apparent value to the customer and something that they are not ready to pay for.
MURA (UNEVEN)
MUDA (WASTE)
MURI (STRAIN)
A customer needs a corrugated carton that can be made using a 50 inch decal reel. Suppose you have a reel that is 51.50 inches which you have in stock
The idea is “go to the real workplace and see.” When I had first started looking into our business, I was given a ballpark figure of scrap that’s generated. This was continuing for quite a while. On a detailed scrutiny we found it was much more than what was being registered and reported (or assumed). What a waste of resources!!! Take a walk in your factory, look around and observe what is happening. Make notes and take pictures. Ask the people manning each of the positions about what they are doing, how they are doing it, how much time are they taking and what kind of problems are they facing. Do not comment, just listen and note. Many would contend that it is our factory and we have set it up. We know what is happening and do not need any walking and seeing etc. Believe me; you will be in for lot of surprises. Have faith and take the walk. It will be totally worth your time.
Mura + Muri = Muda (Waste)
Waste of Resources by Using Two Vehicles
systems have very simple solutions for manufacturing business. They talk of two Japanese terms – Gemba and Genchi Genbutsu. You do not need to remember these terms.
How do we spot waste? It is imperative that there is waste in everything that we do. What is lacking is a critical appraisal. Question is how we spot waste in our manufacturing process. The Japanese management
Try and analyse the layout of your factory. The positioning of machines might be such that they require semiprocessed items to be moved back and forth till the end product is ready. Waste of motion? With waste of motion, often there is another associated waste – transportation. If the required machine setting tools are not kept near the machine in the 5S way, workers might move back and forth with wrenches and other tools or go about looking for them all over the factory. Problem of transportation waste can also occur if you order the wrong decal
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from the paper mill or the paper mill sends you the wrong one. You unload the wrong item from the truck and again reload it after arguing with your paper mill or agent. You have waste of time. You have loss of production in case you are trying for a JIT – like scenario. (Just in time) Another pointer is to look for places where there is no standardization. Often people buy three different types of the same machine over time. It means they have to keep three types of spares at all times. Your cash is tied up. Waste of inventory?
Diagram of 7 Types of Waste People are also biased towards technology. Over automation can lead to processing that might not be needed to generate value for a customer. The production process might not be able to achieve the economies of scale. Waste of over-processing? You might come across people on the scoring or slotting machine idling away. The previous process is yet to give the output while the slotting process has completed its output. It is a common bottleneck. Waste of waiting?
Transportation Inventory Motion Waiting Over-processing Overproduction Defects
How good are your job cards and bill of material? Are they being scientifically managed? If not, you might end up manufacturing 27 cartons instead of the required 25. Your customer is not going to absorb these additional cartons. Waste of overproduction? The worst kind of waste is defect. Take the example of a defective carton. It is delivered to the customer. The customer rejects it. Either you take it back or leave it there. You have to now make a replacement carton and send it to the customer. There is man, machine, material cost and transportation cost notwithstanding the demand of time. And you do not even get paid extra. Manufacturing processes should be well – documented and standardized wherever possible. Use of 5S will be greatly helpful in reducing waste. Implementing visual controls can cut down on miscommunication. System audits should be conducted periodically.
parts of the process while others are idling away. Here we need to understand the throughput level of each system as discussed by Goldratt and try to create a balance (Heijunka) between each process and sub-process.
Balance Among Vehicles The aim of each manufacturing process should be in-process checks to ensure quality. This will reduce the time and cost of production and improve efficiency. Delivering the right quality and quantity of items to the customer in the given time frame is the fundamental key result area for any business. It clearly means greater customer value. Profit will happen as a simple by product.
Starting Point 5S and 3M are the base of Lean Manufacturing. They help in setting the stage for an organizationwide Lean Culture. This concept is extremely relevant for corrugators amongst all other businesses. There is still quite a bit of primitiveness in the corrugation business. It is time for paper mills and corrugators to form a stronger synergy to grow mutually. Synchronizing production processes, raw material procurement and consumption will be pivotal in maintaining low inventory, timely conversion of raw material to finished goods and rotation of funds at each level. Everyone wins. It is established that waste gets generated from the point of unevenness in the system. This leads to overburden and strain on certain
Remember that waste identification and elimination is a continuous process.
Courtesy : Reprinted with permission from Industry Insight – A Technical Bulletin of the Corrugated Industry by House of WICMA
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The Corrugator | April – June 2014 | 83
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11 Ways to Turn Empty Boxes Into Fabulous Fun for Kids Looking for something fun and creative to do with your kids? Got any cardboard boxes ready to recycle? Create some corrugated family fun! The editors of My Kids’ Adventures have searched the Internet to find cool stuff you can make from cardboard boxes. In this article I’ll show you how to “upcycle” cardboard into several different projects that your kids will love. So hold off on that trip to the recycling center and read on for some unexpected ideas.
Why Make Projects Out of Cardboard? Remember when your kids were little and they seemed to enjoy the box as much (or more) than the present itself? Preschoolers and toddlers have a knack for turning a plain old box into a car or a boat or some other kind of adventure. Kids are wired to be imaginative and cardboard is the perfect blank canvas. Feed their imaginations! The fun doesn’t have to end when your kids get a little older. They may just need some bigger ideas. Cardboard can be an awesome
medium for anyone to make something fun out of. It’s free, plentiful, strong yet flexible and easy to work with.
1: Fairytale Castle / Formidable Fortress Bring fairy tales to life with a castle made from cardboard. Your young knights and ladies will love the drawbridge, battlements and other classic features found on this simple design from Kathy Gossen at Cornerstone Confessions. No template is needed for this quick cardboard castle creation that’s large enough for your kids to play inside. We love that you can make this castle your own—just add rooms, paint or decorate according to your child’s imagination.
This time of year, you might have a lot of extra cardboard boxes around the house. Take a look at those boxes and envision your kids creating something innovative and entertaining. Here are some ideas to help. We’ve gathered some fantastic cardboard designs from across the web. For most of them, you’ll need to gather a few basic tools and materials: cardboard, a utility or X-acto knife, a pen or pencil and duct tape or hot glue. Some of the projects are large, some are small. Some require a bit of work and others are so simple you won’t believe you didn’t think of them yourself. Take a look at the size and quality of your boxes to decide on a cardboard project perfect for your kids. Then measure, cut, tape and create some fun family memories.
Trash becomes treasure. Find cardboard around your house and transform it into something fun for your family.
Don’t have a large appliance or furniture box to make the castle? Read cardboard playhouse secrets below (#9) for ways to make a fort from boxes of any size. Check the link at Cornerstone Confessions to learn How to Make a Cardboard Castle.
2: Physics in Action— Ball Drop Maze Have a child who loves engineering contraptions? This ball maze from a happy wanderer is for you. With a large piece of cardboard, cardboard tubes and hot glue, you can easily create this maze.
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Add golf balls for a rolling good time. Your kids will learn through trial and error how to make the balls roll faster and go the direction they need to make this maze work. It’s a great activity for shape identification, predictions (Will it or won’t it roll?), and just some general fun!
4: Stairway Slide Have a gigantic box that you’re not sure what to do with? Turn it into a slide! J. Dix, the Contemplative Creative, explains how to simply cut boxes open, tape them together and lay them over the stairs to create a cardboard slide your kids will love.
3: Music-Making Cardboard Guitar This cardboard guitar definitely had the ‘wow’ factor for us! Make a guitar from cardboard that actually works! How cool is that? Steve brings it to us as part of his Mister Make It and Love It series on his wife’s blog, Make It and Love It. For this project, you’ll need access to a drill, elastic and a pencil, in addition to the obvious items (cardboard cutter and hot glue). Be sure to download the cutting template on their site to get the shape just right. We love that Steve shows how to make a real, working musical instrument out of cardboard. It’s two creative projects in one for your kids—make it first, then play it! A fantastic feature of the cardboard guitar is that the strings are different lengths and when plucked they result in slightly different pitches. It’s great way to learn about the science behind the music.
Make your house a funhouse. Transform the stairs into a giant slide with cardboard and watch kids race cars, balls or even themselves.
What is it about children and stairs? Ours love to sit and read on the steps, create games or drop things over the banister. This cardboard slide will add so many new ways to play. Encourage your kids to roll different objects down the slide: balls, cars, dolls and themselves if you’ll let them! Then watch them up the ante as their creative (and competitive) minds take over and they start to race objects down. Check the link at Contemplative
5: Grocery Storefront Lorraine, or ‘LiEr,’ the blogger behind ikatbag, is known for her many original cardboard creations. Check out her detailed instructions and make this amazing cardboard grocery store for your kids. Make a kids’ dream grocery store with different kinds of boxes. This is the kind of project your kids will play with for years (or as long as the cardboard holds up). Think of all the fun play dates they’ll have with their very own grocery store. With the same instructions, you can make a storefront of any kind: bakery, smoothie bar, lemonade stand and many more.
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This is a fairly simple project that will entice your kids away from the computerand into physical play with friends or siblings. We like that you can leave the box plain (as seen) or “pixelate” it to be more true to the computer game’s style.
8: Horse Stable Have an animal lover at your house? Merrilee at Mer Mag shows you how to make this fantastic cardboard stable for horses, but it’s perfect for any barnyard animal. Change the taped-on decorations for a perfect Barbie house or racecar garage
Check the link at Instructables to learn How to Make a Cardboard Minecraft Mask.
7: Sailing Ships These boats featured on ikatbag are inspired by the Chronicles of Narnia. Their small size is perfect for playmobil characters or other action figures. Blogger LiEr (Lorraine) has made it easy to print out hand-sketched templates to recreate her cardboard boats. Check the link at ikatbag to learn How to Make a Cardboard Grocery Store.
6: Minecraft Head
These boats provide the perfect transportation for all sorts of different animals, people and creatures in your child’s toybox.
This stable is perfect for any barn animal! For this cardboard project, you’ll need duct tape for sure. We love that you can use small- to medium-sized boxes for this cardboard barn. You have the flexibility tomake this any size, depending on the animal your child wants to board.
You’ve loved the Minecraft Treasure Hunt on My Kids’ Adventures. Now your kids can create their own Minecraft mask and act out their favorite video game, live. Instructables contributor Haliburt breaks down this Minecraft box/mask with multiple faces into four simple steps. There are even tips to show you how to keep the box from slipping around on your head. Take Minecraft offline with this role-play mask for kids.
While these cardboard boats aren’t actually seaworthy (or bathtub-worthy), they are perfectly suited for the imaginary adventures of any small characters in your child’s toybox. Make one (or more) with your kids and watch as they set sail on a toy soldier deployment, pirate‘s battle, even a dinosaur rescue mission!
9: Cardboard Playhouse Secrets
Check the link at ikatbag to learn How to Make a Cardboard Boat.
You don’t need to buy a new refrigerator to make a cool fort with your kids, but you
Architect Carl Croft shared his ingenious (but oh-so-simple) tricks for creating cardboard forts and playhouses with any-size boxes right here at My Kids’ Adventures.
Cont. on Page 95 The Corrugator | April – June 2014 | 91
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Cont. from Page 91
10: Beanbag Toss Game Danielle Reiner at made.in.japan fills her site with simple ideas for fulfilling family life. This easy beanbag toss game is a perfect example. Cut any sized box in half, cut some holes and toss beanbags, balls or other small toys into the openings for loads of fun. Create a classic game from a cardboard box. will need Carl’s secret stabilizing material: cardboard tubes. Learn an architect’s simple secrets for cardboard house construction.
See how many variations on this classic game your kids can come up with. Try tossing different things, assigning point values for the different holes or
challenging your kids to toss from different locations. Check the link at born.in.japan to learn How to Make a Cardboard Beanbag Toss.
11: Cardboard Treasure Chest HthrTz posted this cool treasure chest idea on Instructables. The editors there liked her idea so much they posted it on their front page. We love it, too, and couldn’t wait to share this one.
With Carl’s tips, you can make a house, fort, castle, store or any kind of structure using whatever boxes you have on hand. Check the link at My Kids’ Adventures to learn Secrets to Building a Cardboard Playhouse or Fort.
Source : http://www.mykidsadventures. com/cardboard-projects
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Product Profile Diecut Global, a company based in UK offers a range of machines for the Corrugated Industry - Corrufold Series
with alignment device to correct the difference during folding l Machine is controlled by touch screen
and wireless remote control as available for easy operation.
The main features of this Automatic Folder Gluer of the Corrufold Series are given under:
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l This series is especially for folding
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and gluing of corrugated boxes in big sizes. For example computer packaging box and electrical appliances packaging box.
inverter, PLC, belt are imported. of cold / hot glue system like HHS, Valco, ERO, Nordson etc. l Other machine sizes like 1600mm,
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sensors and servo motor to control and register precise position. The speed of the crash lock is monitored by encoder to make sure consistent high speed. l At the folding section, machine folds
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drive can be adjusted and equipped
load cartoning to robotic based wraparound and top load case packing, serves an equally wide panorama of customers made of producers belonging to the world market of food, chocolate, confectionery and consumer goods. 3S PacTec offers customised packaging systems and stand-alone machines to the market sectors served. The specific needs in these sectors show enough similarity to allow for a common product strategy in terms of drive and platform modularity. Particularly their multinational customers benefit from standardisation on global automation solutions as their markets are also global in common characteristics. 3S PacTec brings you the Horizontal cartoning machines COLUMBA ES3000/ ES5000
State – of – The – Art Packaging Technology
3S PacTec Offers Columba ES3000/ES5000 horizontal cartoning machine that comes with servo motors drive, flight belts loader and rotary carton feeder independently.
3S PacTec, Gmbh offers turnkey solutions from one single source starting at the end of the customer’s production plant. 3S has outstanding skills and experience in providing complete packaging solutions by integrating primary, secondary and tertiary packaging equipment at the highest technological level in “Made in Germany” quality. The very wide compa ny ’s portfolio, ranging from vertical bagging, horizontal flowwrapping, top-load and end-
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speeds and a decrease of wear at the anvil and knives.
Other Standard Features include: Size change available within 10 minutes; Hot glue jetting system; Rotary feeder available in 2 head versions; Carton speeds up to 85 cpm - subject to carton size; Servo motors drive, flight belts loader, and rotary carton feeder independently; Slide in and out gates accommodate the extended motorised carton magazine; the PLC touch-screen allows all machine functions, including hot melt pattern to be adjusted; Motorised carton magazine Optional Extras; A variety of different feed and loading options; Additional fixed magazines for each carton size or adjustable magazine available; Wash down style; Tuck-in closure, etc.
While the quality of Polytop MX is always consistent, the hardness and colour possibility is varied. Whereas the market was used to work with black and grey rubbers, PolyMX is the first who introduced a colour-coded hardness range. The new generation of 450mpm corrugator has a reduced energy consumption and with the addition of a special acoustic hood, noise levels in the factory can be considerably reduced.
For More information visit: www.3spactec.com
The MHI also offers the 65J Glue Machine which has gained considerable success since its launch.
A Corrugator with a design speed of 450 mpm
PolyMX ejection material now widely available
Developed with the Steady Stater at its core, the TM450 Corrugator from MHI is the first corrugator to have a design speed of 450mpm. The machine is single knife machine. A broad range of papers can be run on the machine.
PolyMX, Dutch specialist in ejection material for the die-cutting industry, is expanding its presence on the English and Irish market. Starting last month, Polytop MX, the long-lasting ejection system designed especially for the packaging industry, will be available in the United Kingdom via die makers.
Liners range from 80gsm right through to 280gsm, while fluting also ranges from 80gsm up to 200gsm. Thanks to the cassette single facer it can run A,B, C and E flute board, which is an ideal range of board for production of corrugated packaging. Sources confirm that since its commission. The TM450has had a monthly operating average speed of 390m per min.
This means that each hardness has its own recognizable colour. The material is extremely wear-proof, with low surface resistance. During use, the hardness and thickness of the material remains constant. An additional advantage is that the forms for repeat orders are immediately available and can be placed on the die-cutting machine without the need for repair, a fact that reduces changeover and maintenance costs. Polytop MX retains its original form, allowing production to be immediately restarted.
Benefits in the production Polytop MX has become the world’s leading product in the area of long-lasting ejection material for medium, long, repeated and special runs. British and Irish packaging plants can benefit of the many advantages Polytop MX offers. The material has proven to create faster runs with less pressure: with Polytop MX you can reach a reduction of 40% tonnage and 36% increase in running speed. Even though Polytop MX is originally designed for rotary dies, it has proven to be just as successful for flatbed die-cutting. Because of its reliable height and hardness of the material, you can finish the die at one height. This means a stable cutting process with less pressure, higher production
To make the most of Polytop MX, it is essential that the complete system be used correctly. Against that background, PolyMX is the only manufacturer of ejection material to offer installation advice. Partners of PolyMX undergo a strict selection process before they are allowed to supply the system and receive training to raise their technical knowledge to the required high level. PolyMX then continues to support them and supply tailor-made advice. For More information visit: www.polymx.com
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www.seven11industries.com
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Industry News Corrugated’s versatility proves that three into one really will go – A reports by Des King As one of the UK’s leading food producers, Premier Foods makes some of the nation’s favourite and best-known brands including Hovis, Sharwoods, Mr Kipling, OXO and Batchelors, with 95% of British households having one of these products in their cupboards. The enduring consumer appeal of the Batchelors range has made it the domestic market’s ‘easy eating’ category leader. Its soup, pasta and flour mixes have been produced at its long-established 24 strong production-line site in Ashford, Kent which was acquired by Premier Foods in 2006. It has now benefited from a recent development by the corrugated industry. The brand has seen a major overhaul of its transit and display packaging realising an increase in productivity by accelerating time to market while reducing cost. For over 15 years the Ashford site has employed three separate machines per line to insert single-trip plastic ‘W’ trays filled with between 6 – 10 packs into corrugated sleeves that are then shrink-wrapped prior to transit. The combination of a specially customised case-packing system and a redesigned corrugated pack has streamlined the process into a single-stage operation across three production lines.
of 10 cases/min, with efficiency further improved through a notable reduction of bottle-neck. Additionally, one of the lines having previously relied upon hand-filling prior to the shrink-wrapping stage has now been fully automated. The new case-packing equipment has automated size change capability – enabling repeatable format changes in less than 10 minutes – and facilitates excellent operator access with full-length opening acrylic guard doors.
Material gains Enhanced engineering is only one half of the greater efficiency equation. While the specified E flute recycled white outer board rotary die-cut and flexo printed single-colour has slightly increased the cost of the re-designed corrugated retailready pack (RRP), the overall secondary packaging materials bill has been reduced by approximately 50%. This has been achieved through eliminating the need for additional plastic transit packaging, as well as better managing the various different aspects of the supply chain. The E flute’s smoother printing surface also facilitates better print quality – and could indeed allow for additional decorative enhancement should the brand’s forward marketing strategy call for it.
The resultant gains have been impressive, especially so with the fastest of the three lines: a twin-in feed system that has increased throughput by 50% in outputting up to 30 cases / min dependent upon product format.
The machines are able to pack sachets into various different packaging formats as well as four different RRP styles. Low sided and high sided trays, ledge trays and full wraparounds are possible on the same machine without significant change parts. Again, anticipating the potential for future innovation, the option of two piece packaging can also be pursued by adding a lid applicator at a later date.
Meanwhile, the other two lines are geared to maintain an average production rate
In the meantime, all of the material changes to the Batchelors dried foods
packaging that have been implemented to date are fully consistent with the ‘five easies’ criteria with which all effective RRP applications are designed to comply. Corrugated has proved itself time and again to offer the optimum mix of versatility and practicability with which they can be fulfilled.
Ongoing improvement The increase in productivity has been achieved within six months of the replacement equipment’s installation. The drive to seek line improvement is ongoing, says Site Engineering Manager David Grace. “We’ve subsequently automated and applied a corrugated solution in respect of two further lines, each of which had hitherto entailed a manual secondary packaging operation. “While upping front-end speed wasn’t the object of the exercise, as well as reducing packaging costs we’ve been able to better deploy labour away from the bottomend of the process. The net gain of those two factors combined has not only amply justified the capex investment, but by freeing up greater capacity down-line gives us the option to ramp up on production rates at some future time.”
‘Funky’ cardboard polling booths on trial Cardboard polling booths are to be trialled at the European elections in an effort to save cash. Voters in Cornwall will be able to use the new design, alongside the more traditional wooden type. Cornwall county council has bought 700 of the recyclable booths, similar to those used in Australia and the US, costing £15 each. The council’s deputy elections manager Dave Cunningham said they looked “funky”. Cont. on Page 111 The Corrugator | April – June 2014 | 107
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81/1, MATIALA (NEAR ALLAHABAD BANK) NEW DELHI – 110059. Ph. +91 11 25331101 / 2 e-mail: info@electroheat.in, ashujhingan@yahoo.com
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Cont. from Page 107 Voters will choose new members of the European Parliament this week, with councils looking after voting and counts. Mr. Cunningham said: “We have been looking at ways to make elections more affordable, eco-friendly and manageable for our staff. One of the areas we have been investigating is the provision of polling booths. “Both the USA and Australia use cardboard booths and we wanted to see if this would work in Cornwall. As well as being much cheaper to produce, using cardboard booths would also dramatically reduce the costs of storage, transport, cleaning, repairs and replacing e x i s t i n g conventional timber booths at end of their life.”
‘Lightweight’ Wooden booths cost about six times the price of cardboard ones, at £92. Cornwall Council was unable to find a suitable cardboard booth supplier in the UK and it was deemed too expensive to import them from the US. So it hired architects from Exeter to create a design.
Health and Safety - Top Priority In The Corrugated Industry The “World Day for Safety and Health at Work”, once established by the International Labour Organisation, takes place on April 28th. It is a day to promote globally the prevention of occupational accidents and diseases. FEFCO’s aim is to reduce accidents further by raising awareness among its members and by sharing internally their knowledge, experience and ideas. FEFCO believes that learning from each other’s achievements and working together can help to prevent accidents from happening. Therefore, FEFCO has started a structured exchange on accidents information and learnings. Many of FEFCO’s members are actively involved in safety initiatives and there are many impressive examples to share already. For example, the Confederation of Paper Industries (CPI) in UK is reporting dramatic reduction in recorded accidents from Members from 80% above the average for the UK manufacturing sector in 2005 to 5% lower by September 2013. The downward trend is the result of an effective framework put together by CPI and its Members in 2005.
Mr. Cunningham said: “We wanted something a bit different, looked funky, was lightweight, fitted into the back of a car (so the presiding officer could take it with them), was simple to put together, and was strong, robust and appropriate for both able and disabled voters.” The result is a curved, four-person booth which is low enough for staff to see over and around. Each booth also has a low desk suitable for disabled voters. The council will decide after the trial whether to use cardboard booths in future elections.
Another example: for more than 10 years the Dutch Corrugated Association has been working on Safety and Health at work.
In close cooperation with members and labour unions, many projects and activities on prevention of occupational accidents have been initiated and implemented. As a result, the number of lost time accidents diminished spectacularly with over 85% reduction between 2002 and 2013. FEFCO Secretary General, Angelika Christ: “Health and Safety is a top priority for our sector. The challenge for the European Corrugated industry is to achieve worldclass status in Health and Safety through a structured approach and commitment from everybody involved.”
Japan’s biggest box maker in India Oji Holdings Corporation, the fifth largest paper producer in the world and which generated around US$ 12.5 billion in revenues last financial year, commenced the trial run of its packaging unit for corrugated boxes and sheets in Neemrana in May 2014. Throughout its history spanning close to 140 years, the Oji Group has maintained its position as the leading company in Japan and produced 6.6 million tonnes of paper and paperboard in 2012. Oji has entered India by joining hands with JK Paper and Marubeni. After the stake acquisition in 2012, the company is renamed as Oji JK Packaging and holds 60% stake while the remaining 40% is split equally between Marubeni and JK Paper. Oji JK Packaging has set up its plant in Neemrana Industrial Park, Phase 3, Rajasthan with a share capital of Rs.48 crore which is going to absorb an investment worth Rs. 150 crore. With a purpose-built building of 15, 364.18 square metre on a land of 34, 156 square metre, the company is expecting to reach a manufacturing capacity of 34,000 tonnes of packaging products per annum. “We are planning to increase our production capacity gradually in phases instead of delivering 34,000 tonnes in the initial stage. Increasing the production in stages will help us produce the desired quality comfortably and profitably,” says Akio Hasebe, managing director, Oji JK Packaging.
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nil because of the price rise in almost all raw materials, mainly kraft paper, which accounts for 70-75 per cent of the total input cost. In the last two to three months, paper mills have hiked their prices by Rs 3,000-4,000 per tonne in the northern region, and by Rs 2,000-2,500 per tonne in the western and southern regions. Apart from this, the cost of raw material like glue and stitching wire has gone up steeply, and the prices of petroleum products and frequent power cuts and shortage of manpower have worsened the situation.”
L – R: Yoshitaka Nakagawa, general manager – sales; Akio Hasebe, managing director; Yosuke Fujiwara, director controller; and Masashi Kawashima, director – purchasing of Oji JK Packaging in Gurgaon. JK Paper is India’s leading branded paper company and is present in all the highgrowth segments in India, namely, office paper, coated paper and virgin fibre packaging boards. On the other hand, Marubeni is involved in the handling of products and provision of services in a broad range of sectors encompassing importing and exporting, as well as transactions in the Japanese market, related to food materials, food products, textiles, materials, pulp and paper, chemicals, energy, metals and mineral resources, transportation machinery, and includes offshore trading. The company’s activities also extend to power projects and infrastructure, plants and industrial machinery, finance, logistics and information industry, and real estate development and construction. For its Neemrana plant, Oji JK is sourcing its paper from seven to eight major paper manufacturers in India and is not depending completely on JK Paper for its raw material supplies.
Corrugated box industry reeling under margin pressure The industry intends to increase the prices of corrugated boxes by 18-20% in the northern region and by 15-16% in the western and southern regions
The Rs 15,000-crore corrugated box industry is reeling under tremendous margin pressure due to rising input costs and the industry’s failure to raise prices. Manufacturers said that that in the last three or four months, paper mills had raised the prices of kraft paper - the main raw material for the industry - by Rs 2,0004,000 per tonne, but the final consumers (buyers of corrugated boxes) are refusing to pay higher prices despite repeated requests. The industry intends to increase the prices of corrugated boxes by 18-20 per cent in the northern region and by 15-16 per cent in the western and southern regions. They also want the import duty on kraft and waste paper to be abolished. There are over 10,000 corrugators spread across India, with average tonnage conversion of 45 lakh tonnes per annum. The industry is fragmented and dominated by micro, small and medium enterprises (MSMEs), and employs more than five lakh workers directly and indirectly. Ramchand H Arora, the president of the Federation of Corrugated Box Manufacturers of India (FCBM), told Business Standard, “The margin for the packaging industry has shrunk almost to
“Despite all these adverse conditions, customers are in no mood to agree to an adequate price increase. Due to this the box industry is suffering huge losses. If the paper mills keep increasing their prices often and if box users resist a price increase, then many manufactures will have no option but to shut operations,” he added. Industrialists added that the shutdown of this industry would have a drastic effect on the industry as a whole as packaging material is one of the most significant parts of the supply chain. According to a FCBM member, the prices of raw materials like adhesives, stitching wires, and ink have increased by 15-20 per cent in the last two to three months. Besides, transport costs have also gone up, due to hikes in diesel prices. Industry members added that the industry, which comprises thousands of small players, are not united, and therefore are always dominated by buyers. Industrialists mentioned that the corrugated packaging industry has been adequately meeting the packaging requirements of the country by successfully substituting wooden and plywood boxes, thereby contributing to environmental protection and the ecological balance. They expect the government to intervene to resolve their problems. Mukesh Jain, president of the Himachal Pradesh Corrugated Box Manufacturers Association (HPCBMA, a regional association that is a member of FCBM),
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said, “The government should intervene in accordance with the Competition Act, which would help corrugators to procure materials in time and save the industry.” Arora demanded, “We request box users to give minimum 18-20 per cent increase in Northern region and 15-16 per cent increase in Western and Southern region to save the box manufacturing industry. Further, we want the government to save the industry by bringing down the import duty on craft paper and waste paper to zero per cent.” - A report published by business-standard.com
Europe recycles 71.7% of paper and board used in 2012 The European Recovered Paper Council (ERPC) announced an impressive 71.7% paper recycling rate for Europe. In their annual monitoring report the ERPC revealed that current paper consumption in Europe has dropped by 13% to the level of 1998, but the recycled amount of paper is 1.5 times higher than in 1998 - a remarkable achievement. Since 2000 the ERPC has worked consistently on improving the quantity and quality of paper available for recycling. The ERPC monitoring report releases extra insights into the wider context of paper recycling revealing that Europe is the global champion in this field. Furthermore, the ERPC reports that in Europe paper fibre is recycled an astounding 3.5 times a year; world-wide the average is 2.4 times. The report illustrates additional good news. The number of European countries with a recycling rate below 60% has decreased, whereas there are an established 13 countries where paper recycling rates exceed 70%. To increase paper recycling especially in Central Europe, several ERPC members are partners in EU funded projects working to improve collection systems in that region. Commenting on the results of the report, ERPC Secretary Jori Ringman-Beck, said “The European paper value chain devotes huge efforts year after year to simplify paper recycling for citizens and consumers
in offices and at home. The figures in the report prove that paper recycling is truly an industry “made in Europe”. And in line with EU policies it needs to be safeguarded to remain so.” In addition, the ERPC will award innovative technology developments and information campaigns in paper recycling at the European Paper Recycling Awards. The event takes place on 2 October in the European Parliament. For more information please go to www.paperforrecycling.eu
“Research and Markets” Adds a Report on Corrugated Boxes Market in India Research and Markets (http://www. researchandmarkets.com/research/cvv88f/ corrugated_boxes) has announced the addition of the “Corrugated Boxes Market in India” report to their offering. The corrugated box industry is an inevitable part of manufacturing sectors which rely heavily on ample corrugated packaging for finished goods transportation and handling. Despite this importance, the Indian corrugated box industry has faced numerous challenges and hurdles in its growth pace due to the very nature of the industry comprising thousands of small players running manual/ sem i-automat ic plants to cater to the needs of local nearby industries. However, the tide of liberalization and globalization has brought a new ray of hope for Indian manufacturers who are now more willing to upgrade technology and turn into completely automatic lines capable of faster, quality-driven and economical production.
The latest research, titled Corrugated Boxes Market in India, unfolds the market dynamics of the corrugated box industry in India with a major focus on the scenario of automatic corrugated boxes. The report describes in detail the market size of corrugated boxes, market segmentation by large-small players, organized-unorganized market and an estimated regional distribution of players. Vital insights of consumer industries as well as apex industry associations such as FCBM, and regional associations etc., have been obtained and considered while presenting the market dynamics. Industry analysts have studied all the facets of the Indian corrugated box industry to portray a crystal clear picture of the current and expected future market outlook. Major drivers and trends have been identified that will act as catalysts to boost the industry growth besides underpinning restraints in the way of industry growth. Following are a few of the Companies Mentioned in the Report-Cargo International Packagings;- Chaitanya Packaging Pvt. Ltd.;- Chandra Packaging;Horizon Packs; - Srinivasa Cartons & Containers Pvt. Ltd.
About Research and Markets Research and Markets is the world’s leading source for international market research reports and market data. We provide you with the latest data on international and regional markets, key industries, the top companies, new products and the latest trends.
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SinoCorrugated South 2014 A Resounding Success Indian Industry makes its presence at the show SinoCorrugated South and SinoFoldingCarton 2014 wrapped up on April 12 at the Guangdong Modern International Exhibition Center (GMIEC) in Houjie, Dongguan. This year’s combined event was the largest ever, cementing the show’s place as the most important converting industry exhibition in AsiaPacific. The number of visitors through the doors and deals concluded on site were the highest ever. A total of 29,114 trade visitors and over 600 well-known equipment suppliers participated. Many companies chose to debut their new products to the Asia-Pacific market. Automated carton gluing and binding machine; Automated box converting machine; Automated box gluer; the intelligent automated corrugated board production control system are a few of the products that were showcased.
Over 100 Industry Associations Represented Onsite Asia-Pacific Industry Veterans Attended The event was supported by 100-plus industry associations including FCBM. More than 50 organized sizable delegations to visit. Reed Exhibitions felicitated the Indian delegation by organzing INDIAN DAY.
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Asian Corrugated Case Association held its AGM as a synchronising event with SinoCorrugated South 2014. A large number of ACCA Members attended the meeting The newly elected ACCA President, Simon Lo, was quite impressed by the wide range of products on display and said how much the show had helped Association members understand the latest industry trends, while evaluating emerging innovations and solutions on-site. Mr. Harish Madan and others from India represented FCBM and presented their views.
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Forthcoming Events July 18 - 20, 2014
25-27 September 2014
COMPACK is the only dedicated Packaging Expo in the country. The focus is primarily on the end-users of innumerable products - be it Consumer or Industrial, to cater to all the needsrelated to Packaging machines, materials and systems.
International Packtech India
August 7, 2014
2-5 November 2014
8th International Exhibition and Conference for Processing, Packaging and Printing
PACK EXPO International November 2-5, 2014 - Chicago, USA
Bombay Convention & Exhibition Centre Goregaon (East), Mumbai, India
Encounter Innovations for Every Processing or Packaging Challenge
14 - 16 October 2014 TAPPI Training Facility Peachtree Corners (Atlanta Metro) Georgia USA. For more details : www.tappi.org
When you need to meet efficiency benchmarks, roll out a new product, automate or streamline your operations, there’s only one place you need to go for the solutions to get it done: PACK EXPO International 2014.
11 - 15 February 2015
August 23 - 26, 2014
PRINTPACK INDIA 2015
India International Printing & Packaging Fair IIPPF 2014 offers an opportunity of showcasing latest innovations, designs and products, and exchange of technological know-how to both buyers and sellers of printing, packaging and converting equipments. IIPPF has been designed as an international event to meet the aspiration of industry professionals in this sector from all over the world. Hall 18 Ground Floor, Pragati Maidan, New Delhi (INDIA) For more details : www.iippf.com
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INDIACORR EXPO Bombay Exhibition Centre Mumbai, Maharashtra IndiaCorr Expo – SinoCorrugated 2014 is currently running in its second edition and will be organized by Reed Manch Exhibitions in partnership with Reed Exhibitions Shanghai & Indian Corrugated Case Manufacturers Association (ICCMA). Launched last year, the event gathered corrugated packaging industry professionals from across the globe. For more details : www.indiacorrexpo.com/
India Expo Centre Greater Noida, NCR Delhi.
14-17 April 2015
Sino Corrugat
Shanghai New International Expo Center