July - September 2013
Countdown to Corpak
42nd FCBM Conference
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13,14,15 December 2013
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Beyond the Century in Corrugating Lines Over 126 Automatic Corrugated Board Plants Installed across India and Overseas 1st 5 ply high speed (80 mtr. speed) plant in Maharastra Navi Mumbai
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From Single Facers and Creaser Slotters... to Flexo Printers and Rotary Die Cutters Always Ahead Than The Extant...
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2 | The Corrugator | July – September 2013
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.
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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 - Differences in Cutting Die
23 – How to Regulate the chemistry of Ink
E-mail: admin@fcbm.org Website: www.fcbm.org
Please address all correspondence to the Editors at:
31 - FCBM News
41 - TOP 10 Benefits of Corrugated Material
Editors
Ashok Vyas Nalanda Packaging Industries, Mumbai ashokpvyas@gmail.com
Harish Madan Securipax, New Delhi Harishmadan@gmail.com
47- NextGen Vision
55- How to Really Put Clients First
Design & Production:
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Printed at: Rajesh Printouch, Mumbai
65 - AirBond Heat Transfer System for Your Double Backer
85 – Industry News
105 - Products Profile
117 - Forthcoming Events
The Corrugator | July – September 2013 | 5
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
6 | The Corrugator | July – September 2013
HSL-2 Hydraulic Shaftless Mill Roll Stand
50 YEARS IN THE SERVICE OF CORRUGATED PACKAGING INDUSTRY
HD-180 Dual Flute Single Facer
the Editors’ page
Ashok Vyas The falling rupee has been causing grave concern to the country’s economy. There have been fears of an economic emergency. Although the scenario appeared grim sometime back, the 10 point plan outlined by the Union Finance Minister comes as a light at the end of the funnel. The 10 Point Plan to boost growth includes revival of manufacturing sector and promoting of exports. These factors will trigger demand for packaging. The Finance Minister had also said that ‘what we need now is not less reforms but more reforms, not more restrictions but less restrictions’. Meaningful and focussed reforms will surely reverse the economic gloom that has befallen India. There is hope of a rebound in our economy. Industrial output, FDI is up. Exports of Farm Produce has gone up significantly.
We have been receiving compliments on the style and content of The Corrugator. We have introduced a new column ‘What They say about The Corrugator’ in this issue. This will let us know our strengths and weaknesses and help us to improve.
Harish Madan Added to all these the big bang entry of Rahuram Rajan as RBI Governor is sure to infuse positive sentiments as he did on his very first day. In Mr. Rajan’s words “India certainly do not need false optimism… but all the doom and gloom is probably overdone… India is a fundamentally sound economy with a bright future.” The new Governor has sought to assuage market with his action list. He has also emphasized on more credit options for MSMES which again is a booster for our industry. The U.S. Fed’s decision to continue with its bond buy back, as created a wave of optimism. The Indian market is back in the Trillion Dollar Club. All this is good news for the industries. Added to this, growth in agricultural produce and strong rural demand will also be good news for our industry as more and more Fruits & Vegetables are being preferentially packed in corrugated boxes.
This issue carries a feature on the hosting of open house by Pyramid Packaging member of our Karnataka Corrugated Box Manufacturers Association. The Bengaluru – based Pyramid Packaging unveiled India’s first Bobst FFG 618 Quatro Flexo Folder Gluer, which boasts of changing the way corrugated boxes are manufactured in the country.
Mr. Sharad Pawar, Union Agricultural Minister recently stated that fruits, grains and vegetables worth Rs. 44,000 crore are lost every year due to lack of adequate storage infrastructure. Besides building proper stroge facilities and establishing cold supply chains use of proper packaging should be encouraged and enforced. Use of proper packaging, like well designed custom - made corrugated boxes for transportation of agricultural produce will also reduce wastage of food products. In this context, the Haldibari Trial for Packing of Tomatoes conducted by EICMA, comes as a positive step that need to be adopted for other vegetables and fruits. Such trials should be conducted by our Regional Associations to bring in greater awareness on benefits of switching to corrugated boxes for packing of Fruits & Vegetables.
This event underlines the direction in which our industry is moving, which indeed is very heartening. With greater challenges and opportunities opening up as the global leaders come in, the need to modernise and adopt to automation is more vital today than ever before.
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President’s Message It has been a volatile and disturbing period on the economic front. However, the fears seem to be behind us now. Good monsoon all over the country, the 10 point plan outlined by our Finance Minister and the big steps being taken by the new and dynamic Governor of RBI – all these portend good times ahead.
R. R. Ankola
We, Indians are known for our flexibity and versatility. Like the corrugated boxes we make, we have the ability to adopt to all kinds of situations. ========= Our Federation continues to hold its vibrancy.
India along with other emerging markets has got caught up in the global factors. For India, some of the reasons have also been local in nature.
SICBMA is all set to host the upcoming 42nd FCBM Conference at Chennai.
The Government should look at this as an opportunity to undertake structural reforms that are essential for the country to realize its long term potential.
EICMA also had its AGM previous day.
As opined by Mr. Adi Godrej, ‘the silver lining is that the monsoon has turned out to be excellent. The agricultural season should be very good leading to high growth in agriculture which will be beneficial to the rest of the economy with strong rural demand. If we act strongly the GDP growth in the second half of the current financial year, can be restored over 7%. The Hyatt Hotels have converged on India for their first board meeting in the country, signaling the American chain’s faith in India’s growth potential despite a slowing economy. The chain bets big on emerging markets such as India to drive future growth. The Hyatt CEO said “India is a very large market for us behind USA and China. It’s an important current market and is also a very important for the future.” Such and other events underline the global confidence in Indian economy.
We had our Managing Committee Meeting at Kolkata on 31st August.
An interesting pictorial presentation of the 42nd FCBM Conference was made at the FCBM MC Meeting. The Vidarbha Division of WICMA held a seminar at Nagpur. WICMA had also organized its 4th edition of WICMA Symposium at Nashik. I was privileged to be an honoured guest at the Symposium which was well attended. WICMA also brought out its updated Members’ Directory on the occasion. Preparations are underway for updating and bringing out the FCBM Members’ Directory 2013. ====== The Corrugator continues to win accolades from all quarters. I am happy to address you all through this medium of our Federation. I do hope to see you all in large numbers at Chennai.
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Differences in Cutting Die Construction Between Folding Carton and Fluted Material This material was first presented at the April IADD Technical Seminar in Chicago. The presentation was designed to address the questions raised during the January IADD Technical Seminar in California. The differences in cutting die construction between folding carton and fluted material are subtle, but significant. As much as we desire to standardize the tooling, differences in either carton stock or fluted board require the need for more flexibility on the part of the toolmaker. The single most important consideration should be the condition of the equipment being used to convert those materials into valueadded products. The maintenance of the diecutting press is of utmost importance when designing and building tooling. The lack of proper maintenance may hinder the cooperative effort of the toolmaker and the converter. The dieboard or plywood remains basically 5/8 of an inch (15.875mm) thick. It should be noted that in the Bobst manual, page D-2, Bobst recommends 3/4 inch (19.05mm) die base be used in certain situations. While there may be circumstances when this is a good idea, most dies are currently being built using the standard 5/8 inch die board. It is always revealing to watch diecutting presses run in order to gain an understanding of just what is taking place between the cutting die and the stock being converted. One gains great respect for the modern diecutting press which creates tremendous pressures and demands on the tooling and the stock. Because of today’s ever increasing demand for increased efficiency, high speed diecutting is pretty much a given. This has prompted dramatic changes in tooling requirements over the last few years.
Tolerances are tighter, and the need for precision is significantly greater than just a few short years ago. One of the questions that came out of the IADD Technical Seminar in California during the last part of January 1997 was: What effect does flute variance have on die life? While it is not possible to know for sure what the questioner meant by flute variance, let us assume that this is in reference to the various types of fluted board: B flute, C flute, E flute, F flute, etc.. The answer is: Relatively little. The fact of the matter is that correct package design, and the type and condition of the converting equipment, will have a greater impact on tooling than the different types of corrugated board. Even though I am a toolmaker and have been at this for over thirty years, the fact remains that I have never run a diecutting press, and am therefore at somewhat of a disadvantage as I write and speak about diecutting. A diecutting pressman is much more qualified to address these issues. However, I offer some insight into the subject, because I have tried over the years to befriend as many diecutting pressmen as possible. I have done this for two reasons; first, I respect their knowledge and ability, and second, I recognize that they are a major source of information if I want to learn all I can about diecutting. A classic example of this occurred a few years ago when I was called into a meeting of pressmen and supervisors in a foam converters plant. As questions
John T. Gordon, Jonco Die Co. Inc., Minneapolis, MN, USA were addressed to me, I would turn to the press operator, (whom I realized was very knowledgeable about her job) and encourage her to answer the question. What amazed me was that their press operators already had the knowledge needed to run their presses and solve their diecutting problems, yet human nature is such that the organization felt compelled to call in an “expert” (in this case, me). Despite the fact that I did not run presses, I was considered an authority. In this particular instance, all I did was direct the questions to the real authority. This is by no means an isolated incident. Over the course of my more than thirty years in the business, I have seen this scenario play itself out many times. What lesson can we learn from this? Perhaps it is that we need to take the same type of “partnering” approach with our employees, as we do with our suppliers. For the purposes of this article, I would like to address the four elements that must be considered in a discussion of cutting die construction as it applies to folding carton versus fluted material. These four elements are: the cutting rule, the creasing rule, ejection rubber, and creasing counterpart.
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The cutting rule While there are always exceptions, a general “rule of thumb” within the diecutting industry is that folding carton dies are constructed using 2 pt. cutting rule, whereas corrugated dies are constructed with 3 pt. cutting rule. Small fluted board responds well to 2 pt. cutting rule, and if the condition of the press allows, we prefer it.
Figure 1
Figure 2 If a press is not level or if the chase plate is warped or bowed, (Figure 1) it may be necessary to use 3 pt. rule because the uneven cutting conditions can cause the rule to be flattened after the first few impressions and 2 pt. cutting rule may bend over. (Figure 2). The type of rule used for a small fluted board job should be determined early in the process, and with full knowledge of the condition of the press. High speed diecutting requires cutting rule that consistently cuts cleanly, with minimum pressure, allowing for maximum through put of the press. As a result of this requirement, steel rule manufacturers have tightened their tolerances and created new products to help the toolmaker. One example of such products is 42 degree beveled rule, a variation from the more common 60 degree (American Standard) or 52 degree (European Standard) beveled rule. (Figure 3).
cuts almost all the way through the paper and then “bursts” it apart. The last bit of separation is not a cutting action at all, but rather, a “breaking apart” of the fibers that hold the sheet together. While the degree of bevel may, or may not, be a critical factor for most applications, the sharpness of the cutting rule will always be a critical factor in successfully diecutting any material.
Figure 3 Forty-two degree rule is an attempt to duplicate the advantages of long bevel or faceted rule. It has long been known that when diecutting thick material, the secondary bevel, which makes the blade thinner, will allow for easier penetration of the stock and improve ejection of the diecut parts. Some dies are being built today using 42 degree rule. A number of converters like it and are convinced it helps; others say they see little or no difference. It depends on the application and the particular needs at the time. A good illustration of this can be found in our experience making tooling to cut gaskets. A few years ago when for health concerns, asbestos was removed from all gasket material, gasket makers found the replacement material difficult to cut and experienced dramatically shortened die life. We spent a considerable amount of time experimenting with both hardness and bevel of rule. In this particular instance, we achieved a fair level of success using extra hard, steeper beveled rule. Late last year we toured a major Japanese steel rule manufacturing facility. The production processes were so advanced and automated, that one could not help coming away impressed. Our first impression was that they were shaving the rule, but upon questioning, we were informed that the rule was being ground. The advent of precision, high speed grinding with heat treating on the fly, and the resultant availability of very precise ground rule gives toolmakers and converters options that did not exist just a few short years ago. Let us consider for a few minutes the cutting of paper in a platen diecutter. The knife blade enters the stock and cuts. It
Diecutting fluted board presents unique challenges. Fluted material consists of a flat liner, then a wavy medium and then another flat liner. These three are held together with starch, which is applied at the corrugator during the corrugation process. As with carton stock, it is imperative that the cutting rule be sharp, because the rule will first cut the initial liner, then the medium and then it will begin to cut the last liner, finally “bursting” it apart. (Just as we observed above when we talked about diecutting carton stock.)
Figure 4 Dull, damaged, or flattened knife will cause damage to the stock and create excessive dusting or angel hair. (Figure 4) This becomes critical if the cartons being produced are for food or pharmaceutical products. Electronics packaging also requires extreme cleanliness. In fact, most of the boxes manufactured today require clean diecutting. In an effort to minimize dusting, rule manufacturers offer various coatings. These coatings are effective in some applications. Once again, we emphasize the need for level presses and good maintenance programs to keep diecutting equipment in excellent running order. This is a necessary discipline if the diecutting process is to reap full benefit from the technological improvements of modern diecutting tooling.
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A number of years ago, rule manufacturers introduced shaved rule. This was met with considerable enthusiasm within the industry. The advantage for the manufacturer is obvious, with the potential for increased production, and the ability to hold tighter tolerances. The advantage for the converter is less clear cut. We know from our experience in manufacturing tooling for corrugated, carton, and the specialty markets, that there are a lot of materials that require the use of ground edge material as opposed to shaved edge. Whether the rule is ground edge or shaved edge, the most significant factor is that it must be sharp, and the best way to achieve this is to ensure that the press platens are well maintained, and level enough to kiss-cut.
Selecting Creasing Rule There are four important elements to consider in a discussion of cutting die construction as it applies to folding carton versus fluted material. Last month we considered the cutting rule, next month we will discuss the role of ejection rubber and creasing counterpart. This installment examines the role of creasing rule in various applications.
The creasing rule When a cutting die is designed to cut and crease fluted stock, it is important to select the appropriate creasing rule for the application. Innovations in rule manufacturing have resulted in a greater number of choices. The complexity of today’s work resulting from changes in converting technologies and processes, and the expanded use of recycled fiber, must be considered when making this selection. In a long standing practice within the corrugated industry, boxes are usually diecut from the inside(non-printed side) of the box. Unlike the folding carton industry, which has always had to counter all the creasing rules in a die, corrugated converters seldom use creasing
counterpart to improve the fold ability of the crease. Creasing has traditionally been accomplished by using a heavy enough crease, plus hard rubber on each side of the crease rule as needed. The dynamics of creasing change significantly when converting small fluted board. While internal packing or simple brown boxes can still be diecut in this manner, most other small flute applications will respond well to other approaches. We encountered an excellent case in point a few years ago when we built the tooling for a six out, reverse tuck, E flute box which was glued after the diecutting operation. An expensive litho label was laminated to the sheet, adding another layer of paper. To our knowledge, this customer had never run a job like this one, and had first considered diecutting it on one of their soft anvil rotary diecutters. We urged them to consider running it on their Bobst after some discussion, they agreed to do so. We built the cutting die using 2 pt. cutting rule and 2 pt. creasing rule. It was decided to diecut from the printed side. We introduced this customer to phenolic counterplates. Together with their press crew, the job was set up and the counters installed. The job was successful, and the boxes went through the gluer with a minimum of rejects. Despite the success of the project, I sensed that the plant and especially the press crew were very uncomfortable by the number of changes a project such as this required. It is a basic aspect of human behavior that when we get too uncomfortable in a new behavior, we tend to revert back to a more comfortable one. This proved to be the case in this instance. Some time later, the same job came up again and was scheduled to run on the second shift. The crew had not been adequately trained, and, fearing the new technology of the counterplates, decided to use creasing matrix. As one might suspect, the job was a disaster. The crease height was not designed for creasing matrix. They lost a lot of boxes at the gluer and had some unhappy management people. I would venture a guess that quite
a number of people reading this can relate to this story. It illustrates the need for both parties to take responsibility for the outcome of a project, and to partner in the truest sense. We used 2 pt. crease for the job in the story just related. It worked, and it is fitting to use 2 pt. crease in some applications. We know of converters using 3 pt., 4 pt., and sometimes 6 pt. creasing rule successfully. Each one can be an appropriate choice for different applications. This reinforces the need for flexibility in our planning. It is important to have some discussion and to come to a clear understanding of just what will be required of each crease score. An understanding of the product options when selecting creasing rule benefits everyone from the converter to the end user. One of our choices is between flat top crease and round top crease. (Figure 1)
Flat Top Crease
Round Top Crease Figure 1
Flat top crease is flat with the corners broken so as not to rupture the corrugated stock. It seems to work best against the flutes. Round top crease rule has a full round top and works best with the flutes. This is because it has a high center profile resulting in consistent folding. Some want to use a flat top crease while other converters are more comfortable using a round top crease. Is there a right and a wrong? It’s difficult to say, but one principle to bear in mind is this: Consistently use what works best to control the fold for gluing. We had a meeting to discuss the contents of this article. I wanted to get feedback from the people at Jonco who deal with these issues every day. I asked how to totally
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eliminate cracked scores. The unanimous answer left us all laughing. They replied as if it had been rehearsed, “Don’t fold it!” While it’s easy to appreciate the humor in the response, anyone involved with converting fluted material can also recognize the element of truth as well. Despite the inherent challenges of achieving consistent quality scores, the right combination of rule, ejection rubber and either creasing matrix or counterplates can eliminate cracked scores on most jobs. Some situations will tax our experience and knowledge to the limit, yet while we may never be totally satisfied, I believe that the right combination will produce acceptable results. It seems that every time we talk about this subject in a meeting, someone will ask, “How do you prevent laminated labels from cracking when creased?” I wish I could provide a simple formula that would work every time. Unfortunately, I cannot. If the label stock is poor quality, dried out or laminated with the wrong adhesive, it may be next to impossible to eliminate cracking entirely. Some coatings are very difficult to crease without experiencing some cracking and flaking from the cutting rule. Another concern that is frequently raised involves cracking on a dark, UV coated litho laminated label with double crease rules. A successful technique used on E flute is to diecut from the printed side and replace the double crease with a single, 6 pt. crease. The bead created by the counter results in a double score effect and usually works well. Our experience tells us that it is best not to lay down hard and fast rules, rather, to allow some flexibility in deciding which is best for each project. Ejection Rubber and Creasing Counterpart here are four important elements to consider in a discussion of cutting die construction as it applies to folding carton versus fluted material. In the first two installment of this series, we examined the elements of cutting rule and creasing rule. In this, the final installment, we will
discuss the role of ejection rubber and creasing counterpart.
Ejection rubber For the purposes of this article, I would like to discuss two basic types of ejection rubber, “open cell” and “closed cell.” Open cell rubber is best described as resembling a sponge. (When compressed, the air is squeezed out of it; when released, the air returns, and the rubber resumes its former shape.) Recovery speed is slightly slower than “closed cell” rubber. Closed cell rubber has tiny gas bubbles sealed all through the material. When it is compressed, it bounces back quickly (much as a spring). It is quicker and generally better quality rubber than open cell.
rubber or variances from the standard. Heavy corrugated board and double-wall corrugated board often are cut from dies built using 1/2” (12.700 mm) plywood. This is to give the rubber “compression” room. It is important to use the right rubber to do the job without destroying the integrity of the material being converted. There are a variety of rubbering techniques. Each technique can be appropriate for different applications. A common technique is to lay the pieces, end to end, with a 1/4” (6.350 mm) gap between each piece. (Figure 1) Figure 1
Tooling designed to diecut various types of corrugated board generally uses open cell rubber to eject diecut parts from the die. Soft anvil rotary dies have always used closed cell rubber, in part, because of its longer life, but also because of its rapid recovery. We are seeing an increased use of closed cell rubber in platen diecutting. This increased use can most likely be attributed to greater consistency. In addition, the modern platen diecutting press, with its higher speed, takes full advantage of closed cell rubber’s rapid recovery. Rubber, in addition to rapidly ejecting the diecut parts, also plays a significant role in holding the sheet firmly in place during the cutting cycle. We do not want to see movement of the diecut parts in the press during the cutting cycle. On page D-13 of their manual, Bobst recommends that rubber be 1/16” (1.5875 mm) away from the cutting knife. When parts are nicked together it is absolutely necessary to keep the ejection rubber about 1/16” away from the knife. Also, Bobst recommends that ejection rubber be 1/16” over the height of the cutting rule. Basically, this is the standard most cutting dies follow. It should be noted that special circumstances will call for special
Most litho labels and high quality direct print being converted today require great care in selecting the proper ejection material and placing it correctly on the cutting die. If the rubber makes tracks or embosses the finished box, it decreases the value and is not acceptable. Often, solid strips will cause less damage than pieces, as the gaps between the pieces may show up on the finished parts. One technique applied in such situations uses solid strips of rubber along each side of the cutting rules. (Figure 2)
Figure 2
One of the challenges we frequently encounter is the proper ejection of boxes with large panels. It is always tempting to
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install small rubber pieces in the center of large panels in order to lift the sheet, to do so, however, significantly increases the risk of dimples or emboss marks. This will be readily detected if the box is held up to the light. We have found that a good way to avoid this is to use a sheet of very soft rubber in the center of large panels. There are two important aspects to consider when converting packaging: esthetics, (the general appearance of the packaging), and the degree to which structural integrity and structural strength is necessary. On a recent trip to Toys ‘R’ Us (In order to forestall any speculation concerning my mid-life crisis or a second childhood, I would like to state, for the record, that we have ten grandchildren), I noticed that most of the toys were packaged using small fluted board. In this application, esthetics are extremely important, while structural integrity and stacking strength are not major considerations. In a different setting, say, a warehouse club type store where packaged products are stacked two or three high on a display pallet, structural integrity and stacking strength are crucial. Unlike carton stock, fluted board has a tendency to crush in the areas where ejection rubber is applied. Since the strongest part of the carton is the corner, selection of the proper crease rule and ejection rubber in these areas is important. Ejection rubber also plays a significant part in the overall appearance of the package. Improperly placed ejection rubber can mar the sheet and give the finished package a shoddy appearance.
Creasing counterpart The two prevalent options available to counter the crease rules for small flute applications are prefabricated creasing matrix and phenolic counterplates. Creasing matrix comes in either strips or rolls. While it will not produce the same results as phenolic counters, the perceived cost difference make this attractive to many converters who use both phenolic and strip counters. Counterplates can have a definite, positive impact on auto gluing
and can also eliminate the cracking of most scores when folded. On longer runs, we recommend counterplates rather than strip counters. Another question coming out of the Technical Seminar had to do with the problem of station sorting diecut loads before gluing. Obviously the questioner had experienced a multiple out cutting die where the outs were not producing exactly the same part and would not feed through the gluer unless separated and batched per the out number. If it is proven that the cutting die is accurate (balanced both as to rule and properly installed ejection rubber), the next aspect to question would be the condition of the diecutting press. If a four out cutting die is properly constructed the press is level and in good operating condition, then the four outs should be the same.
Conclusion Based on my experience in over thirty years in the industry, I have observed that some diemakers build generic tooling for just about every application. This is understandable, given the economic pressures brought to bear by customers and the difficulty in managing a die shop that is dedicated to building custom tooling. It’s much easier to construct tooling to rigid standards than it is to work with individual converters on individual jobs. However, it is very rewarding when the professional toolmaker is allowed to integrate his newest technology into the tooling, thus enabling his customer to be a more productive organization. As tool makers, our responsibility to our customers is to help control and reduce their production costs. Many times, investing a little more in the tooling will save production costs. We do not serve our customers well when we succumb to the pressures of competition and build tooling that is less than we are capable of, simply because we fear we can’t get paid for it.
Looking ahead Because of the concerns about repetitive trauma disorders and the high cost
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(and universal shortage) of hand labor, it is likely that most packaging in the future will be set up by machine. I believe that the combination of automatic machine set up equipment and tooling that is custom designed to fulfill specific folding applications will, ultimately, result in packaging or products that will function efficiently for both the converter and the end user.
This article is reprinted with permission from the International Association of Diecutting and Diemaking’s monthly magazine, The Cutting Edge, August 1997. The IADD 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 area. Visit www. iadd.org or call 1-815-455-7519 for more information about IADD.
John and Joann Gordon founded the Jonco Die Company in 1965. Today Jonco primarily serves the packaging industry by supplying Flat and Rotary tooling and related services for corrugated converters and Flat Dies, Stripping and Blanking tooling and related services for folding carton converters. Jonco has always been an innovative company seeking ways to improve tooling and offering ideas and techniques to customers in an effort to continually bring improvement to the process.
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How to Regulate the chemistry of Ink In this past series of articles where I have been discussing ink, my intention has been fairly consistent in discussing methods and technical guidelines in producing boxes with fine printing in this competitive market. As an industry, we certainly have to be focused on exactly what our customers are asking for regarding printing, color consistency and product description on their shipping containers. Now, this new article is going to have a focus on the mechanical side of regulating the chemistry of ink. As box producers of “multicolor” shipping containers, we have to focus on the mechanics of printing while at the same time managing the chemistry side of the process. Over the years, there have been many discussions on ink and its use. We have had discussions on its properties and how they relate and react to each other. I am going to discuss and present common denominators that are usually over looked and frequently missed. I am going to discuss and review the following categories: 1. 2. 3. 4.
Printing Plates (Clichés) Ink Fountains (Plumbing System) The Anilox Roll The Print Station (Pull Collar vs. Vacuum Transfer) 5. Ink Maintenance.
the sheets, 4. We order the ink and 5. Have qualified crews on hand to run the orders. We then design and order the printing plates specifically for each job. The plant spends a great deal of time and expertise in producing these plates in order to satisfy customer’s requirements. These plates frequently cost a great deal of money depending on how many colors and the design of the printing itself. Many times, the cost can exceed $8,000- $10,000 US per set. We spend this kind of money and make a commitment as we usually expect great results from these multicolor processes. In order to assure this success, we need specific guidelines on how we purchase, receive, maintain, clean and store these expensive tools. Their exact performance is based on proper care and handling. They also must be cleaned and washed with a proper detergent, stored properly and then delivered to the press side in a condition ready for production.
Dick Target On Target Consultants Cleaning: The detergent that we use to clean the plates should have a pH no higher than 10.5. Remember, that the highest pH of the ink that we use is 9.5 pH. A cleaning material with a maximum pH of 10.5 is certainly adequate enough to re-wet the resin and pigment particles in the dried ink itself in order to purge the system of the old ink. If we introduce a detergent to the printing plates with a pH higher than 10.5, we will cause a chemical reaction with the photopolymer material and cause it to be sticky. The sticky surface of these plates actually says that the surface is no longer smooth. This means that there are microscopic highs and lows on the surface of the plate, which directly results in poor ink release characteristics. With poor ink release characteristics on the plate surface,
1. Printing Plates I always consider the printing plates the final two inches of the process yet a very important part of the program. Our printing plates are generally made out of photopolymer material and they do require some minimal maintenance and continuous care. We, as an industry, do a great job with all the legwork for our customer’s orders that we process in our plants: 1. Sales negotiate the order 2. We have the necessary equipment in the plant, 3. The corrugator produces
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24 | The Corrugator | July – September 2013
the result is poor printing, wrong colors and miss-prints. The crews then have to increase impression roll pressure resulting in smearing, poor register and impossible trapping. A recommended pH for the cleaning material is between 9.5 and 10.0. Storage: Printing Plates should always be stored in the round or at least hung up by grommets on the ends of the Mylar. Never store them laying down flat. During their own manufacturing process, these plates are designed to perform in the round on print cylinders. Their own environment says that the relationship of the printing plate and the Mylar should always be in a round environment. If they are flat, bubbles and air pockets can and do develop between these two (Plates and Mylar) due to their improper handing and storage. The end result is they not only have a short plate life but they will also produce poor printing as well.
In many cases, it is better just to change the hose with a new one with the correct inside diameter and move on.
3. Anilox Roll The anilox roll in the print station is the same as the corrugator rolls in the single facers. They must be understood, properly maintained and cared for so that they have a good life delivering the proper volume of ink to the printing plates on every order. In the perfect world, each and every cell in the anilox roll should evacuate completely every time it comes in contact with the surface of the printing plate. This is one of the ways we control color in our process. The volume of ink in the cells also determines the color and the shades we print. We must consider this point when we transfer jobs from press to press. The anilox rolls should have the same volumes in order to print the same colors, press to press.
happens in the working area of the anilox roll and then it needs to be replaced. (Note: A high percentage of the Anilox Roll business today is “Repair Business” caused by poor handling and process damage by the crews)
4. Print Stations In our industry, we generally use several different types of print stations. One design says they are built with Pull Collars or another one is designed with a Vacuum Transfer System. These are both unique and they both offer different opportunities for the box plant. They also offer very different air environments for the Flexo Ink that we use. A Vacuum Transfer print stations offers a high volume air environment for the ink. The Ink suppliers should be told this as they need to supply an ink with slower reacting amines in order to maintain the proper realigy of the Inks. Pull collar print stations have a more static air environment
2. Ink Fountains: We always want to be sure that the plumbing system (pumps, hoses and filters) are kept clean and free of excess resins, dried pigment particles and paper dust. It is important that the ink that we use flows freely through the print station with minimum distraction and interference. The system should also be designed so that minimum air is introduced into the process. Frequently, we see bubbles in our ink buckets. We then add “anti-foam” to fix this problem. (Bubbles cause poor ink transfer onto the printing plate which results in lost color.) Anti-foam is an acid based material. This reduces the pH of the ink and this can and will cause pigment / resin separation in the bucket. The antifoam product is a band aide. Fix the problem! Reduce the air pressure; relocate the return lines to the side of the bucket and not the center of the pale and clean the filters. It is also very important to review and inspect the hoses that we use in the print stations. Be sure that the inside diameter of the hose itself is not reduced too much because of separated and dried resins.
We should also be very aware of the pH of the detergent that we use in the cleaning process. The maximum pH of the detergent should be no higher than 10.5. Anything higher than this number will start to cause mechanical separation between the ceramic coating on the anilox roll and the substrate (Roll Body) itself. The results are cell failure, inadequate ink transfer and poor printing. Also, please be careful in choosing the mounting straps that you use in mounting the printing plates on the print cylinder. There have been times when these metal clips have fallen off and then are transferred into the anilox roll nips. The roll is then damaged. This always
and just need normal speed amines in their inks. The other major design is the wiper roll vs. the chamber doctor blade system. They both produce some normal heat in the process. However, the chamber doctor blade systems generate more heat than the two-roll wiper system. Again the ink supplier needs to be an integral part of the manufacturing process in order for the box plant to purchase the correct design ink so that they properly and accurately satisfy their customer’s printing requirements.
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26 | The Corrugator | July – September 2013
5. Ink Maintenance Vacuum Transfer
With all of these discussions regarding the mechanical side of ink, we must not forget to be pro-active in maintaining the proper chemistry (REALIGY) of our inks during the process. Our plants spend a considerable amount of money every year on their inks. The crews and supervisors should have an active, easy to manage process whereby we assure ourselves that we are getting the maximum performance and consistency from our inks. An easy
solution is for the ink supplier to offer a “pH adjuster” for the crews to use and add several ounces of this product to the ink bucket “once an hour”. A process that is coordinated with the ink companies, crews and managed by the supervisors will assure the plant of a successful and profitable process where everyone wins. Be smart, properly plan and enjoy your job. Chamber Doctor Blade System
Ink Fountain Anilox Roll
Wiper Roll
Pull Collar
Printing Plate
Print Cylinder
Pull Roll Impression Cylinder Ink Drain System
Wiper Roll / Pull Roll Print Station
Dick Target, owner of “On Target Consultants” in Lower Gwynedd, Pa., has been in the corrugated industry for 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 This article was first published by “Corrugated Today November/ December 2012” and is reprinted here with the author’s permission.
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Put the Seal of Quality on Your Packaging
Trust Linux
Testing is an integral part of Quality and Quality Assurance that of success. In a competitive world, it is the Quality Assurance that sustains business and wins customers. Participating as your partners in your endeavour is Linux – makers of Quality Testing Equipments. Linux Testing Equipments, incorporating the latest innovative technologies, help you to assess the properties of raw materials as well as finished packages. In a short span of twelve years, Linux has earned the trust and confidence of leading manufacturers and users of packaging, across India. Your needs for package testing equipments will continue to drive our initiative and product innovations. An attestation of our customer - centric approach.
Super Model
Comprehensive range of Testing Equipments for measuring : Bursting Strength Box Compression Edge Crush Ring Crush GSM / Substance Puncture Resistance Water Absorption (Cobb) Moisture Content Tensile Strength Rub Proofness Tear Strength Stiffness Strength Caliper Thickness Drop Resistance Vibration Resistance
Micro Print Model
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.
GSM (Substance) Tester Two Models : l Electronic model with 5 sample size measurement l Manual model with 2 scales of 0-250 & 0-500 gsm.
Gann Moisture Meter
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
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FCBM News The event was also marked by the 4th FCBM Managing Committee Meeting at the same Venue. Shri Milan Dey specially thanked Shri R. R. Ankola, President, FCBM and also extended a warm welcome to the FCBM Managing Committee Members for their gracious presence on the occasion.
“New Team Elected at the 41st AGM held at The ITC-SONAR on 30.08.13” Shri Milan Kumar Dey, has been elected as President for the current year for the year 2013-14. In the course of his Address, Shri Dey mentioned that ‘a President is only as good as his team’ and felt that with the co-operation and support of the Managing Committee Members, the Association would continue to render prompt and effective services to all members and grow stronger in the coming years.
Mr. Hemant Saraogi, speaking on the occasion
FCBM President, Shri. Rajendra R. Ankola, congratulated Shri. Milan Kumar Dey on being elected as President of EICMA and spoke at length on the contributions of EICMA to the parent body.
EICMA Office Bearers 2013-14
President Milan Kumar Dey
Vice - President Narendra Kr. Jhunjhunwala
An interesting A/V presentation highlighting the 42nd FCBM Conference was presented. The President, EICMA requested EICMA members to participate in the 42nd FCBM Conference, scheduled at Chennai.
Mr. Bharat Kedia Outgoing President greeting Mr. Milan Dey the Incoming President of EICMA
Hon. Secretary Mohit Bajaj
Hon. Treasurer Rajendra Chokhani
Mr. Milan Dey addressing the Gathering
Section of audience
The Corrugator | July – September 2013 | 31
FCBM Managing Committee Meeting at Kolkata
The 4th FCBM Managing Committee Meeting was held on 31st August 2013 at Hotel ITC Sonar in Kolkata. The Managing Committee deliberated on various topics related to the developments in the industry. It was decided to issue an All India advertisement in major newspapers informing customers of the steep rise in the costs of manufacturing Corrugated Boxes and the need to increase box prices if the CB industry is to survive. Shri Ashok Vyas, Chairman of the Membership Directory Committee requested Regional Presidents to help to compile the contact details of members in the format that would be sent to them
by the Secretariat. He also appealed to members to canvass for support by way of advertisments. Shri. Ramchand Arora, FCBM V.P. I, gave a presentation on the 42nd FCBM Conference being hosted by SICBMA. He announced that the Conference would be held on 13 – 15th Dec. 2013 at Hotel Leela Palace, Chennai. Conference Dockets and Participation forms were circulated and Shri. Arora invited all members to attend the Conference.
At the Cultural Programme a group of talented singers entertained members with ghazals and nostalgic melodies in Hindi and Bengali. This was followed by Dinner.
Other routine matters were also deliberated The sub-committee meetings were held on the previous day followed by EICMA Annual General Meeting.
FCBM Office Bearers on the dais 32 | The Corrugator | July – September 2013
FCBM President presenting mementoes to EICMA Members
Managing Committee Meeting in progress
Ram Arora, Vice President I, FCBM Making a presentation of the 42nd FCBM Conference
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Mr. Raju R. Ankola President FCBM being felicitated by Mr. Binoy Basu Mullick
Mr. Raju Ankola President FCBM addressing the members
Members of Managing Committee interacting
Cultural Programme regaled the members
FCBM Grievance Committee As members are all aware, FCBM has constituted a Grievances Committee under the Chairmanship of Shri Santosh Lath. Members having any grievances to be addressed may please contact the chairman. - Editors
34 | The Corrugator | July – September 2013
WICMA SYMPOSIUM 2013 – A resounding Success
WICMA Office Bearers for 2013-14
WICMA Symposium - the Western Region’s Annual Event for Corrugated Box Makers, was held on 26-27September 2013 at the Express Inn, Nashik. Mr. Baldev Mehta, Chairman, Symposium, in his welcome address highlighted India’s top position in the production of Fruits & Vegetables and the need for appropriate packaging of fresh fruits and vegetables.
26 – 27 September 2013 Express Inn Nashik, Maharashtra
Shri. Bharat Parekh President
Shri. V. M. Chaudhary Vice President
Shri. Deenu Shetty Hon. Secretary
Shri. Sachin Keni Hon. Treasurer
Mr. Shrirang Sarda, a noted industrialist was the Chief Guest. He congratulated WICMA on organizing such a Symposium and bringing together the fraternity of box makers in Western India. Mr. Ashok Vyas, Chairman Membership Directory Committee presented the WICMA Members’ Directory 2013 for release by Chief Guest The Directory was well appreciated by all members present. Shri. Pritambhai Parikh, the veteran of the industry was honoured with the presentation of Lifetime Achievement Award to the resounding applause of the members.
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Over 200 delegates participated in the symposium – which indeed. Is a great success to WICMA and the Nashik Division. In the Two Technical Sessions eminent speakers deliberated on: Packaging of Fresh Fruits & Vegetables, Upgrading of Corrugated Box Plants. Coordination with Paper Dealers was the third session and the fourth session was on SHOP TALK.
Pinning the New President
WICMA AGM in Progress
A section of Audience At the Annual General Meeting, a new WICMA team has been elected for the year 2013-14 with Shri. Bharat Parekh as the new President. Shri Anil Kumar Reddy, made presentation on the forth coming FCBM Conference at Chennai A gala cultural programme was organized on 26th September along with Cocktails & Dinner.
Dancing with Joy
36 | The Corrugator | July – September 2013
Haven’t You Registered Yet? Fill in the Form overleaf
The Conference & Exhibition for the Corrugated Packaging Industry
42nd FCBM Conference
The Leela Palace Chennai, India
13,14,15 December 2013
INNO
AT I N G
into the Future
The 42nd Conference of the Federation of Corrugated Box Manufacturers of India – CORPAK INDIA 2013 is being orgainsed. The event will witness the congregation of over 1000 plus corrugated box manufacturers from across India and neighbouring countries. The Conference is being structured with Technical Sessions, interactive meetings, entertainment programmes and sightseeing trips. The Technical Sessions will have presentations by leading experts from India and across the world, who are authorities in their fields. All in all the CORPAK INDIA 2013, will open up new ideas and new thoughts that will help growth of our industry by Innovating into The Future.
The Corrugator | July – September 2013 | 37
42nd Conference of Federation of Corrugated Box Manufacturers of India The Leela Palace, Chennai - India l 13, 14, 15 - December - 2013 Chairman, Registration Committee RAMKUMAR Y. + 91 99402 88662 reg@corpakindia.org
Registration
Date: _____________________
Photo
Photo
Name of the Participant
Mobile No.
Name of Spouse
Mobile No.
Photo
Name of Child (Below 12 years) Please use separate form for each Participant & Family
Organisation
Phone
Address:
Fax E-mail
Name of the Regional Association : ____________________________________________________________________ (For FCBM Member) Payment Details : Please (√) box Cheque
Draft
RTGS
NEFT
No.
Dated
Drawn on /Deposited in Bank,
Branch
for Rs Fee
S.T. @12.36%
Total
Rs. 7,000/-
Rs. 865/-
Rs. 7,865/-
Member’s Spouse/Child
Rs. 5,000/-
Rs. 618/-
Rs. 5,618/-
Non Member
Rs. 10,000/-
Rs. 1,236/-
Rs. 11,236/-
Non Member’s Spouse/Child
Rs. 7,000/-
Rs. 865/-
Rs. 7,865/-
Foreign Delegate
USD 200/-
Note:
Registration Fee per Person Member
Signature
1. Cheques/ DDs should be drawn in favour of SICBMA CONFERENCE A/C and sent to SICBMA Office. 2. Alternatively, cheque/cash may be deposited at any branch of BANK OF MAHARASHTRA. as per details mentioned below: Account Name : SICBMA CONFERENCE A/C. Current A/c Number : 60139176083 Bank Name : BANK OF MAHARASHTRA, ASHOK NAGAR, CHENNAI - 600083. | MICR Code: 600014006 | IFSC Code for: MAHB0000676 3. For confirmation, copy of receipted Bank pay-in slip or NEFT/RTGS counterfoil must be sent to SICBMA Office with full transaction details, by email or post. 4. For Registrations received after 30th. November, 2013, Registration Kit will be given subject to availability. 5. Cancellation of registration : Refund of 90% upto 10th November 75% upto 10th December, Nil after 10th December on Basic Fee.
Organisers & Hosts:
South India Corrugated Box Manufacturers’ Association
B-28, 6th Floor, P. A. Apartments, 869, E. V. R. Salai, Kilpauk, Chennai - 600 010. INDIA Tel.: +91 44 2641 5926 | E-mail: corpakindia@gmail.com
38 | The Corrugator | July – September 2013
www.corpakindia.org
What They say about ‘The Corrugator’ April - June 2012
Double facer upper Viscosity : Relative high Gelpoint : 56-58ºC Solids : 26-28%
C Flute single facer Viscosity : Relative low Gelpoint : 61-63ºC Solids : 21-22%
CORRUGATED
INDIA 2012 Vision - Gen Next Conceive... Create... Customise. Double facer lower Viscosity : Relative medium Gelpoint : 58-60ºC Solids : 24-25%
E Flute single facer Viscosity : Relative Medium Gelpoint : 61-63ºC Solids : 28%
41st FCBM Conference - Mumbai
I am a student of IIP Hyderabad. Myself very much interested in corrugation. Please support me to get this magazine properly. Kindly send «The Corrugator» Magazine ASAP. Thanks for the valuable support once again
Tony Pinnington
J. Hari Prashanth. Chennai -600019. Tamil nadu.
3rd Managing Committee Meeting of FCBM at Bangkok
Please don’t see this as criticism but constructive comment. There is obviously a lot of work going into the preparation and presentation of such an excellent publication. Maybe the readers and industry in general could help you make it even more appealing.
Thanks for your mail. I have received the Apr-June issue of the Corrugator and was impressed by your editing skills. It was really nice to read such high quality content related to corrugating industry at one place. Hemant Jain, Jainsons Packers, New Delhi
Thank you, I have now received the latest Corrugator. On a personal note I was interested to see you have used an article by my daughter! As to the presentation, I am not perhaps the best person to judge, but I get the impression that it is crowded with almost entirely either long erudite articles. I have expressed my concern at the lack of cohesion of the Indian operators before and appreciate you may have some difficulty in gaining their cooperation in supplying ‘newsy’ brief information notes on the various challenges, be their skills, manpower, technical, operational, materials, machines, transport, marketing etc etc, that they face, or good news about new applications, developments, markets etc.
“The Corrugator” is a nice magazine. Make sure that you show the reader clearly what is what. In general a magazine contains several types of information: Articles e.g. of the auditor providing a vision on the market, a meeting or seminar. These mostly do not write about how the process works. Articles describing the process written by an independent source (this is what I do). They have to make sure to be scientifically correct. The aim is to challenge the readers mind set and help develop and innovate processes. Mostly people feel insecure reading this because they are of technical nature and sometimes explain things that go against common belief. I presume you know all this. Wilbert Streefland, Technology Coaching, BvVA, Belgium
We received your January-March issue thank you! I look forward to reading it and sharing it with everyone in our office. Jenny Holliday Membership & Desktop Publishing Assistant International Association of Diecutting and Diemaking (IADD) USA
The Corrugator | July – September 2013 | 39
www.dicar.com Sole Agent
Delhi Office: C-3/16, Rajouri Garden, New Delhi - 110027. INDIA. Tel. +91 11 4668 1488 | Mobile: Harish Madan +91 98736 23248 E-mail: info@oneworldinc.in | harishmadan@gmail.com Regd. Office: A-147, II Floor, Road No. 24, Wagle Industrial Estate, Thane (W), Maharashtra - 400 064. INDIA | Tel.: +91 22 2582 1054 E-mail: bombay@oneworldinc.in | Mobile: Raju Ankola +91 98210 31084
40 | The Corrugator | July – September 2013
TOP 10 Benefits of Corrugated Material in Packaging Corrugated packaging is one of the most flexible and innovative packaging solutions available on the market today. Made through computer engineering by “fluting” arches of paper between two or more stabilizing liners, it provides a remarkable variety of solutions for a company looking to package their products. It is the most popular packaging material in the shipping world, and the reasons are easy to see. It has a long and proven history. Corrugated cardboard has been used reliably as a packaging material since the 1870s. It’s never been replaced in standard use in all that time because of its demonstrated superiority.
It is reusable. Many corrugated fiberboard packages are made with flexible corners, so that the box can be collapsed and then used again. Consumers like it for this reason, and cost-focused companies can also reuse it to save money.
It adds little to the shipping bulk. By being so light and thin, corrugated material keeps additional shipping costs to a minimum when other, more costly solutions also tend to be significantly heavier.
It is inexpensive. Fundamentally, corrugated fiberboard is made of nothing but paper and air. It is cheap to produce and easy to buy in bulk quantities.
It is renewable. The most common material used for corrugated fiberboard is pine tree pulp, and pine trees are both easy to grow, and fast-growing as well.
It is recyclable. Another reason corrugated packaging is among the most innovative packaging solutions available is that it is primarily made from recycled materials and can be reused almost indefinitely. It is among the most “green” packaging solutions a company could choose.
Ken Wheeler Corrugated Packaging Solutions
It is extremely versatile. Fiberboard can be used to safely package anything from toys to wine bottles. It can also be used in stand-up floor displays, wall hangings, and a variety of other advertising purposes, making it truly one of the most innovative packaging solutions available.
The Corrugator | July – September 2013 | 41
Sole Agent
Delhi Office: C-3/16, Rajouri Garden, New Delhi - 110027. INDIA. Tel. +91 11 4668 1488 | Mobile: Harish Madan +91 98736 23248 E-mail: info@oneworldinc.in | harishmadan@gmail.com Regd. Office: A-147, II Floor, Road No. 24, Wagle Industrial Estate, Thane (W), Maharashtra - 400 064. INDIA | Tel.: +91 22 2582 1054 E-mail: bombay@oneworldinc.in | Mobile: Raju Ankola +91 98210 31084
42 | The Corrugator | July – September 2013
It is surprisingly strong. The fluting of the material, much like arches in a cathedral, allows the material to be flexible and still quite strong. The bursting strength on a piece of fiberboard is usually hundreds of pounds per square inch. It can be printed upon easily. Because the outside of it is flat cardboard, many printing options are available for dressing it up. Digital printing, lithographs, screen printing, even full-color metallic ink and more are all possible. Virtually any design can be put onto corrugated cardboard. It cannot damage the materials inside. An individual piece of fiberboard is soft and cannot harm what it protects, even fragile glass goods. It lacks any sharp corners that could damage what’s inside, or people handling it.
Any business looking for a versatile, durable, and innovative packaging solution needs to look no further than to simple corrugated fiberboard. With its proven track record of success, there is hardly any reason to turn to other materials for any packaging needs.
RISING INPUT COSTS CRIPPLE CORRUGATED BOX INDUSTRY Kraft Paper, the industry’s major raw material, has been subjected to multiple and prohibitive increases. The mills have cited the massive depreciation in Indian Rupee as the prime trigger for such hikes. The extreme volatility on the paper price front has impacted smooth functioning of all the units.
Advertisement on effect of rising costs on corrugated Packaging released in Economic Times
On one side the paper mills are raising prices relentlessly and on the other side all our critical inputs, like Starch, Wire, Fuel, Diesel, Manpower costs etc. are climbing swiftly. This industry, primarily, operating in the small and medium sector, is currently reeling under tremendous cost pressures and its’ very survival is at stake. The cumulative impact of hike in all input costs comes to 15%. Corrugated box industry has been an integral part of the India growth story. Almost the entire common man’s basket of essential goods need Corrugated Boxes for its’ packaging. Besides this industry promotes and protects the environment and is totally eco-friendly. We appeal to our esteemed clients and end-users for their support and cooperation by granting the appropriate increase in the cost of Corrugated Boxes to avert the closure of the units, which is imminent on account of huge cash losses. Immediate action by all stakeholders of this important industry would help to
avoid any disruption in supply chain.
Federation of Corrugated Box
Manufacturers of India
138, Mittal Indl. Estate No. 3, M. Vasanji Rd., Andheri (E), Mumbai-59 e-mail: admin@fcbm.org | www.fcbm.org
The National Apex Body of The Corrugated Packaging Industry with 12 Regional Associations & 2200 Members
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NextGen Vision: Business - A Game of Poker Poker and business offer unparalleled profit opportunities for those who are positioned to capitalize on them. The skills that bring you success while playing cards can also help you know when to fold ‘em or hold ‘em at the negotiating table. Business is NOT a chess game where two people with equal resources deal with each other and the individual’s skill level determines the winner. In chess, your emotion plays no role in affecting your opponent. However in Business negotiations, parties do not have the same resource to compete with & they come from different emotional states. One side may be very desperate to get a deal done while the other has enough money to wait out the deal and see if something better comes along. The individual skill in such settings is how you use your resources and emotions and play with the hand that has been dealt to you. This is poker at its finest. The world of poker is the real world. Risk and reward are measured every second of the game. There is no better training ground for Business than a Poker game, where your ability to think strategically and make split-second decisions determines whether you cash out a winner. While both have a large element of chance, in the long run the winner is the man who plays with steady skill. In both games ultimate victory requires intimate knowledge of the rules, insight into the psychology of the other players, a bold front, a considerable amount of self-discipline, and the ability to respond swiftly and effectively to opportunities provided by chance.
Two cards we are dealt denotes our Strength & Weaknesses. Five cards on board are the opportunities, threats, Government policies etc common to all the players. Ideally our Strength should merge with opportunities to give us a winning hand. But if our cards are stronger, we principally hope that the cards on deck are neutral or weak so that a weak player need not take advantage of the same. How true in Business as well. Winning at Poker and at Business both rely on sitting at the right table, identifying where you have a positive edge, measuring your odds, trusting your instincts, escaping the “sunk cost trap”, bluffing when required and committing to constant learning and improvement.
Right table selection gives initial edge to a successful player In business, choosing the right business (Corrugation or otherwise) depending on the stakes involved (Automatic or Semi) and skill of other players (Competition) will determine your long run survival (Business Goals). Also just like you have a positional advantage from players seated to your right, in Business your proximity to your clients will give you the initial edge. Remember that you also have the option to change tables (Diversification). Unlike Poker, in real life, you can also define your own Table (Branding & Product recognition). In this context, also
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remember that while analysing your competitors, never under-estimate irrational & inexperienced players. It’s a lot harder to win from them because their moves cannot be predicted. These tips are invaluable in saving you unnecessary bets and losses to your Business and even when your cards are not favourable; it will give you necessary foresight to follow the correct path. Success Mantra: Identify the Positive Edge, Measure your Odds & Trust your Instincts. In business, it’s your competitive advantage that gives you the edge over your competitors and maximizes your chances of success. Successful Businessmen always combine their experiences, the odds and the non-verbal cues they observe into a situational analysis, and rely on their gut instinct and their market knowledge to make major business decisions.
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Escaping the sunk cost trap A common mistake of both Poker players and Investors is to hold onto a poker hand or investment because they have already invested a lot and they want to at least get their money back. We should understand that the money in the pot is no longer ours no matter how much we have already put in. We should always refresh the status with every raise & call irrespective of previous round. How often we stick to a failed client just because we were not able to come out profitably in the last transaction or already made printing blocks & paper investment on his behalf. Our instincts & ability to analyse the current status is important here otherwise it might eventually lead to further losses. Successful Players & Businessman know how to get rid of these hands when they are in danger & strategically make a graceful exit as there are more rounds or opportunity to come. In these challenging economic times, it’s of the upmost importance for us to evaluate all aspects of our business, and be willing to fold underperforming divisions, regardless of the time, effort and investment devoted to them.
POKER FACE & BLUFFING : Essential to the Game We often bluff our clients by giving the wrong Cost breakup. Paper price more than the market rate & Conversion Cost lower than the actual. Let me relate an interesting conversation I had with a client friend over a couple of drinks. He said he knew we are quoting them a higher Paper Price but also accepted that we have quoted a fair price for their cartons. They have knowingly allowed that because they know they can’t get a better price from Market and by allowing this bluff, they know we will always be in their grip, a kind of psychological pressure that will always remain with us just because the rates are based on a lie. I wondered then whether we are actually bluffing them or merely calling their Bluff. Remember: Bluffing, though a form of Lying, does not reflect the morality of
the Bluffer if it is an integral part of the game. Bluffing in business is regarded as a permissible game strategy - much like bluffing in Poker. “If you can’t stand the heat, stay out of the kitchen.” Cunning deception and concealment of one’s strength and intentions are vital in poker and Business.
Place Bets & Raise Strategically ‘APPLE Inc ‘ , for instance, I’m sure, has already come up with the future models of I-phone 6,7... and so on. But they are placing their product I-Phone 5 now. Their strategy is to upgrade gradually so as to derive maximum revenue from the Market. In Poker lingo, they are Raising bets smartly. The idea is to ‘Take what you want & not just what your opponent gives you’.
We live in the most competitive civilized societies. Our environment demands a high degree of aggression in the individual’s striving for success. Business is Learning & Improvement: our main area of competition, and it has Regardless of our success or achievements, been ritualized into a game of strategy. The we can never stop learning & improving basic rules of the game have been set by the based on the past experiences and government and as long as a company does exposure. Innovation & Upgradation is not contradict the same, it has the legal a must in any Business Environment and right to shape its strategy without reference we can never do today’s job by yesterday’s to anything but its profits. If we’re going method & be in Business tomorrow. to stay in business, In essence, each we have to look for hand you are dealt profit wherever the in poker is like a law permits. We don’t product whose value make the laws. We you are trying sell obey them. We’re to the rest of the not in business to table by placing bets, promote ethics. raising them, and Look at the cigarette calling other players’ companies, for God’s bets. “In a winning sake! If the ethics hand, figuring out aren’t embodied in how best to price the laws by the men things to give who made them, “I don’t know how they play poker on yourself maximum you can’t expect businessmen to fill your planet, but we don’t eat every player value is something who bluffs us.” that’s exactly what the lack. you do in a poker If a man plans to take a seat in the business hand, and it’s exactly what you do when game, he owes it to himself to master the you’re trying to sell something in business,” principles by which the game is played, including its special ethical outlook. To However unlike Poker, In Business be a winner, a man must play to win. This Environment, everyone can be a winner does not mean that he must be ruthless, & take home some part of the proceeds of harsh or treacherous. On the contrary, the the game. better his reputation for integrity, honesty, A successful businessman must follow and decency, the better his chances of & remember the following Golden victory will be in the long run. But from Rules of Poker:time to time every businessman, like every poker player, is offered a choice between l You’ve gotta love the game. To become certain loss and bluffing within the legal really good, you need to live it and rules of the game. In such a crisis he should sleep it. definitely bluff-and bluff hard.
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LOANS
“I’ll be playing poker Monday through Saturday. But don’t worry, I’ll spend Sunday with you, watching videos of
okay, how were you planning to repay the loan assuming you don’t win the world series of Poker?
me playing poker.”
l The guy who wins the most hands is
l You need to adjust your style of play
not the guy who makes the most money in the long run. l Make sure your bankroll is large enough for the game you’re playing and the risks you’re taking. l Remember that it’s a long-term game. You will win or lose individual hands or sessions, but it’s what happens in the long term that matters. l Don’t play games that you don’t understand, even if you see lots of other people making money from them.
throughout as the dynamics of the game change. Be flexible. Don’t go ‘All In’ assuming the Market will favour only you. Learn by doing & surrounding yourself with talented players. Theory is nice, but nothing replaces actual experience. Be nice and make friends. It’s a small community. Share what you’ve learned with others. Look for opportunities beyond just the game you sat down to play. ou never know who you’re going to
OBITUARY
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Shri Ved Prakash Goel was born in the year 1921. He did his Post Graduation in Commerce and became a Professor in Meerut College. The corrugated industry was in its nascent stage then, and the other industries were not familiar with the advantages of Corrugated Paper Boxes. That was when Shri Ved Prakash Goel, in the year 1956, introduced Corrugated Paper Boxes to such companies as Hindustan Lever Ltd. for packing soaps.
Shri Ved Prakash Goel 1921 - 2013
In 1962 he explained the advantages of Wax Coated Corrugated Boxes to the Defence Sector for paradropping supplies. The Defence Sector then used these Wax Coated Corrugated Boxes to paradrop
meet, including new friends for life or new business contacts. l Have fun. The game is a lot more enjoyable when you’re trying to do more than just make money. l Project the Right Table Image. Mohit Bajaj is a well known corrugator. He is the Managing Director of Lakshya Packaging Pvt. Ltd. He is the Hon. Secretary of EICMA. and an active members of FCBM His articles are a blend of humor & practicality.
supplies at NEFA and Ladakh during the time of the China War. It was in 1967, he started his own unit in the name of Packwel Service and later on also Goel Packaging. He took keen interest in the foudation of our regional association, WICMA and our all India body, FCBM. He served as the Hon. Secretary of FCBM for many years. He passed away at the grand age of 93 years on 7th of June,2013. He was fondly addressed and will always be remembered as “PROFESSOR” by his friends and colleagues.
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The Corrugator | July – September 2013 | 53
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54 | The Corrugator | July – September 2013
How to Really Put Clients First: 11 Steps to Change Your Biz We put the customer first. We’ve heard it (and probably said it) so many times it’s become a cliché. And yet, while we pay lip service to the idea, few companies truly put it into practice. The fact is, we’re so concerned with bottom lines, profit margins, and paying the bills (at work and at home!) that we instinctively put ourselves first. But as counterintuitive as it may seem, Joseph Callaway says that anxious sense of self-preservation may be exactly what’s holding you back. “When you really put the customer first, and put your own needs second, a whole lot of other things naturally fall into place,” notes Joseph Callaway, who, along with his wife, JoAnn, is the author of the new book Clients First: The Two-Word Miracle (Wiley, October 2012, ISBN: 978-1-11841277-0, $21.95). “Tough decisions practically make themselves. Since you’re no longer pitting the client’s needs against your own, relationships are based on transparency and honesty. People like and trust you and referrals flow freely. “If there is a magic bullet, putting clients first is it,” he adds. “It has the power to change your life, to transform your business, and to bring about financial security.” He should know. He and his wife built their thriving business, Those Callaways, in a tough industry that’s had more than its share of challenges. Their book describes their late-in-life entry into the world of real estate, how they had their “Clients First” revelation, and how it has impacted their professional and personal lives. It also gives readers step-by-step advice on how to put their own customers first, as well as why each one works.
fellow realtors never recovered. We have sold over a billion dollars’ worth of homes. “And we credit it all to our remarkable—and remarkably simple—discovery of putting clients first, whether they were individuals or institutions. Even through the darkest days, our clients kept calling our phones and coming to our open houses. They took care of us just as we had taken care of them.” But what does putting clients first REALLY look like? Read on for all eleven parts of the Callaways’ transformative Clients First principle:
Step One: Make the Commitment. For many people, “commitment” is a scary word—and for good reason. It implies that you have accepted responsibility, that you
Joseph Callaway & JoAnn Callaway Co - Authors of Clients First Scottsdale, Arizona are “locked in,” and (sometimes) that you have given up an aspect of your freedom. For all of those reasons, and many more, most commitments should not be taken lightly. But here’s the good news: Because sincere commitments require you to step up and take a stand, they often lead to great things. “If you’re comfortable with your current level of success, are satisfied with the way you do things now, or don’t really have a desire to be more involved with your customers, Clients First is probably not for you,” says Callaway. “It goes against the grain of human nature. We instinctively focus on ourselves, not others. Saying ‘yes’ to Clients First will change the way you think and interact, and initially you might find this shift difficult! But in the end, I promise, your new way of doing business will make everything else easy.”
“JoAnn and I entered real estate in 1996 when interest rates were almost 9 percent,” Callaway recalls. “Since then, we have lived through a bubble and survived a horrible economic downturn—and managed to prosper through both, while many of our
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HOW-TO HINT: Give yourself a week to think it through before you decide. A no is better than a quick yes and a shallow commitment. Ask yourself, What will my life really look like when I put customers first? Will I have to work late more often? Take client calls at home? Have conversations that veer away from business and into “personal” territory? If you don’t like what you envision, don’t make the commitment.
Step Two: Speak the Commitment.
Step One—Make the Commitment— won’t ultimately mean much if you don’t share your intentions with others. If you say nothing, your commitment will begin to wither like a potted flower that isn’t watered. However, speaking your commitment gives you strength, and it’s instrumental in affirming (and reaffirming) to yourself what your goals are and why. “JoAnn and I found that sharing our intentions to always put clients first with our employees, with colleagues, and with clients themselves made them ‘real,’” Callaway recalls. “Speaking this commitment makes others think more highly of us, and it makes us think more highly of ourselves. It keeps us on the proverbial straight and narrow. Unless we want to prove ourselves to be liars, we have to ‘walk’ what we ‘talk.’” HOW-TO HINT: If you get a negative reaction when you speak your commitment, channel David Letterman. The late-night TV host often reads jokes from index cards. If one happens to fall flat, he simply flicks the card away. This flicking gesture protects him from rejection. If someone dismisses your spoken commitment (or worse, mocks it), make a flicking gesture and move on.
Step Three: Keep the Commitment. Some days, you’ll want to say, “To heck with this difficult person! He can fend for himself from now on!” Or you might just be so tired and overwhelmed that you’re
tempted to cut some corners and let some non-priorities slide. According to Callaway, you must try as hard as you can to resist the temptation. “Clients First is something you must consciously recommit to every day,” he affirms. “Remember, it’s usually not the big things that trip us up; it’s the little steps we miss. One day you let an aggravating client get to you, for example, and the next you’re pre-judging a walk in. Eventually, though, keeping your commitment to Clients First becomes easier. It’s a habit that will become hardwired into your life. And by that point, the benefits, rewards, satisfaction, and success will be rolling in—and you’ll be proud of the person you’ve become.” HOW-TO HINT: Remember the Napoleon Hill story from his classic Think and Grow Rich. A miner worked a claim for years before eventually giving up and going back home. A few years later an amateur visiting the area found a pickax and gave a promising wall a try. In less than an hour, he discovered one of the West’s richest strikes. Don’t stop Three Feet from Gold!
Step Four: Get Yourself Out of the Way. When it comes to being successful, having a healthy ego can be a blessing and a curse. Yes, you need a strong sense of self in order to avoid being trampled on and marginalized by competitors and by clients. But when you start to believe that winning, recognition, and accolades are “the point” of what you do, you’ve veered off onto a destructive path. “Everybody is different, and everybody will develop different ways to redirect their egos,” explains Callaway. “What’s crucial is that it happens; that you get out of your own way. Remember, your job is to be a champion for your clients, to solve their problems and find them satisfying solutions. Your job is not to be the most important person in the room or to put others down. Believe me, when you take
care of your clients first and foHOW-TO HINT: Notice how often you bring the story around to yourself. Stop doing that. Many people think building rapport is a matter of finding a common interest. They then dominate the common interest discussion by talking about themselves. Don’t. This is a form of arrogance and it takes your focus off the client.
Step Five: Set the Monkey Down The monkey that’s riding your back in the form of responsibility and pressure, that is! If you’re like most people, you probably feel burdened with a myriad of worries, fears, and obligations. You assume that “it’s all up to me,” and you might even lie awake at night fretting over what isn’t right and what could go wrong. However, if you want to successfully care for your clients, you can’t be expending the majority of your mental energy on yourself. “I’m not saying that putting the monkey down is an easy or instantaneous process,” Callaway clarifies. “Far from it. It’s challenging to break what’s often a lifetime’s worth of mental habits. But here’s the beauty of Clients First: Success is no longer about you; it’s about your customers. Your challenge is to only do the best for your clients. It’s a win-win situation, because the clients put their faith in you and you put your faith in doing your best for them. In our experience, everything else usually works out for the best.” HOW-TO HINT: Every time you find yourself fretting, do something for a client. Spend an hour solving a client problem you’ve been avoiding. Connect one client to another who might be able to help him. Email him a link to an article you know would interest him. Worry thrives when you procrastinate and handwring. Action is the antidote…so do something (anything) to back up your commitment to your clients.
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Step Six: Put Your Faith in Others. According to Callaway, this has two meanings: serving others and then letting others serve you. Serving others means separating the service you render from the paycheck you receive. No, don’t give your services away for free; just make sure that padding your bank account isn’t your primary motivation. In other words, do your job because you genuinely want to help your clients, and don’t worry about what you’ll get in return. (When you have this mindset, you’ll probably find that your clients feel just as strongly about compensating you fairly!) “Yes, putting your faith in others can sometimes be a leap of faith,” Callaway admits. “Sometimes you will be left holding the bag, and there’s nothing you can do about it. But more often, you’ll have opened yourself up to winning in a situation where reluctance might have caused you to fail.” The second aspect of putting your faith in others, says Callaway, is allowing them to help you by delegating tasks or leveraging others’ talents. No matter how good you are, you can’t do it all. “And when you trust others and give them the freedom they need to do their jobs, you’ll usually be pleased with the results,” he adds. remost, they will take care of you through their loyalty and appreciation.” HOW-TO HINT: Practice going first. The next time you find yourself in a position to serve someone—a boss, an employee, a client—take the leap. Don’t wait for them to do something for you. Don’t think about what you’re going to get in return. Don’t ask yourself if the person “deserves” it. Going first is a way of putting your faith into action. Your faith will be repaid. Miracles will drop from the sky. Step Seven: Trust the Truth. If someone accused you of not being honest, you’d probably have the same reaction the Callaways did before discovering Clients First: “How can you even ask that? Of
course I’m honest!” And by most people’s standards, you probably are. But it’s also likely that you aren’t being totally, completely authentic in the way you handle relationships and do business. “Before deciding to put clients first, JoAnn and I didn’t always trust the truth,” Callaway admits. “We feared consequences. We feared not being in control. We tried to make things happen according to our plans, we held back, and we sought to manipulate—all with the best of intentions. Now things are different. We trust the truth that Clients First is best for everyone, and our definition of honesty changed. We feel it, and our clients feel it too. They’ll say, There is someone who will take care of me, tell me the truth, and put me first. They know we aren’t going to pull punches or hold anything back.” HOW-TO HINT: You know that thing you’ve been wanting to say for a long time? Go ahead and say it. Don’t worry about the fallout. Bravely take the leap. You’ll find that most people want the truth. Give it to them and you’ll be joined together in a bond that never betrays.
Step Eight: Let the Work Be the Reward. In the real world (and especially in a tough economy), you can’t always follow the popular graduation day advice and “do what you love.” But what you can do, regardless of how you spend your nine-tofive hours, is choose to take pride in your work. When you consciously decide to put forth your best efforts, you’ll experience greater rewards and you’ll get better at what you do! “With Clients First, this step is fairly easy, because you focus on the work and often forget about money, time, and perks,” Callaway explains. “You care about doing the job right for your clients, and you feel wonderful when you know you’ve accomplished that. Whether you are a CEO or installing break pads, you can learn to love what you do in that you feel pride in your work and strive to be better. Having
any other attitude will only make you miserable and drive clients away.” HOW-TO HINT: At least once a year, do something that will help you get better at your job. Maybe it’s going to a seminar. Maybe it’s asking the client how you can serve him better. Maybe it’s shutting down your email so you can better concentrate on the task at hand. The better you get at what you do, the more rewarding it will be. Step Nine: Learn to Like People. Even if you already consider yourself to be a people person, chances are you still need to learn to like them more. Think about it: Do you see your clients as business opportunities and sources of income, or do you see them as actual human beings with likes, preferences, quirks, and stories? To truly put clients first, your number one goal at each meeting should be to invite them within arms’ length and make them less of a stranger. “People want to do business with individuals they like—and they like people who like them!” Callaway points out. “Now I’ll admit—sometimes it’s not easy to like people. They can be difficult or have bad attitudes, and they can be a source of pain, ridicule, and embarrassment. But if you get out there and engage, you’ll find that most of them are just like you: filled with worries, hopes, and dreams.” HOW-TO HINT: Every time you meet with a client, ask at least one question that has nothing to do with business. Ask about their kids. Ask about their pets. Ask about their favorite food, or movie, or vintage car. The conversation will likely develop in a surprising direction. As you hear their stories and get to know their joys and sorrows, you’ll start liking them. And you’ll find it more natural to put them first as clients.
Step Ten: Turn It Around. You, not the customer, are the expert on your business. You are the one who knows how to sell real estate or market a product or properly install a heat pump. But does Cont. on Page 63
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60 | The Corrugator | July – September 2013
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Cont. from Page 59 that mean that yours is the only opinion that matters? Of course not. No matter what industry you’re in, you need to turn your viewpoint around and make a sincere effort to see yourself and your business as your client does. “I once worked with a vendor who asked me to help him develop advertisements for his home-cleaning business,” Callaway recalls. “The problem was, he would consider only ads modeled after his favorite sports team’s branding. He didn’t care that not all potential customers were sports fans, or that they might root for a different team. And as a result, his business hasn’t grown much. Don’t make this man’s mistake. Don’t make your business all about you. Think about what your clients want and figure out how to give it to them. Bottom line: When you turn it around and put yourself in the client’s shoes, you put the client first.” HOW-TO HINT: Call up an ex-client and ask her how she sees your business. Assure her up-front that your goal is not to win her back. You just want the truth about how she perceives you and the truth about what she as a customer really wanted from you. If you are willing to do this (and make no mistake, it’s hard), you’ll learn a lot about what needs to change.
Step Eleven: Give to Get. We’ve all heard the expression, “The more you give, the more you get.” And we understand its meaning when it comes to things like love, smiles, and kindness. But how does it relate to business? Well, you can give your clients honesty, competence, and care, and hope to get those things back. But if you give away your expertise, time, energy, and (gasp!) money, won’t you just go broke? “Not necessarily,” says Callaway. “I remember being very apprehensive about donating a large sum of money to build a Habitat for Humanity house as a Christmas gift for our clients. I thought I’d never see that money again. But in the years since, I’ve learned that new clients chose us—and even that a bank gave us all of their foreclosures to sell—because they had learned of that donation. Now, you might not always give and get on such a large scale. But the principle works for all amounts of money, and it also works when you’re giving over-and-beyond service. “Understand that giving to get isn’t like a financial transaction where you give and get right there and then,” Callaway adds. “There is no up-front agreement on what you’ll receive or when you’ll receive it. It may take time. But rest assured, whatever you give will come back to you with interest.”
HOW-TO HINT: Look for something to give away. (And don’t be cheap about it!) Whether you give free popcorn to moviegoers or a free grooming to pet boarding clients or a gorgeous framed print to your interior design clients, you make them feel special. This will keep them coming back. “As you’re implementing each step, remember that Clients First—like life itself—isn’t so much a destination as it is a journey,” Callaway concludes. “If you commit to it, Clients First is a path you’ll be traveling for the rest of your life. It will fill you with pride, clarify your perspective, and promote your business’s prosperity. Most of all, your clients will love you for it—and you will love them!” This article is reprinted with permission from the International Association of Diecutting and Diemaking’s monthly magazine, The Cutting Edge, August 1997. The IADD 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 area. Visit www.iadd.org or call 1-815-455-7519 for more information about IADD.
Joseph Callaway and JoAnn Callaway are coauthors of Clients First: The Two Word Miracle and founders of the real estate company Those Callaways.
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AirBond Heat Transfer System for Your Double Backer What is AirBond ? AirBond is the Only Heat Transfer System for your Double Backer accepted by the key International Corrugator Machinery Manufacturers.
Mr. Andrew Jarrett, This is based on a Technical Presentation made by Mr. Andrew Jarrett, JKSP Services Ltd., UK, made at 41st FCBM Conference held in Mumbai and hosted by WICMA
It replaces all Weight Rolls and existing Shoe Systems. AirBond was designed and developed not only to remove all the problems that Weight Rolls and existing Shoe Systems were giving, but to provide operator and production teams the best controls to accommodate all paper grades from micro flute lightweight 70gsm upto 440gsm double/ triple wall, giving the ability to increase production to meet the demands of today’s customers.
Weight Rolls Do not provide the correct or sufficient even pressure to optimise the heat transfer process. De-lamination, Blistering, Wash Boarding and Warp problems occur due to poor and inconsistent heat transfer into the board, thus slowing down your production, increasing production costs with the additional problem of having to recycle more waste. Loose & out of balance Weight Rolls With Weight Rolls, edge crush is significant and this waste production is unacceptable. When running narrow width paper, weight rolls offer no adjustment, the same pressure is applied across the web, this in turn creates unnecessary wear to the belt and heating plates.
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Weight Rolls – Full Width Board Weight Roll
Heating Plate Uneven Distribution of Pressure Poor Bonding Across the web
Edge Crush
Edge Crush
Weight Rolls – Narrow Width Board Weight Roll
Edge Crush
Heating Plate
Belt & Heating Plate Ware
Uneven Distribution of Pressure Poor Bonding Across the web
Belt & Heating Plate Ware
Cont. on Page 71 The Corrugator | July – September 2013 | 67
One World... Many Opportunities !! Corrugated Packaging Industry in India is undergoing a change, from the hitherto used manual manufacturing process to fully automatic manufacturing technology. Keeping pace with the ever demanding customers, this change is inevitable. It is our considered opinion that State of the Art Technology is not necessarily best suitable in all circumstances. With over three decades of experience in the trade, OWI offers the appropriate technology to the Indian Corrugated Packaging Industry. OWI can proudly say that it has contributed substantially in driving this makeover. It offers appropriate, cost effective solutions on up gradation of technology. OWI offers Consultancy in Green Field Project, Process Controls, Productivity, Crew training, Additives, Coatings, Machinery Selection & Sourcing, Engineering Modifications. OWI has experienced professionals on board who can deliver the results. OWI represents companies from all across the world who offer most suitable technology, in the Indian context. All the companies that we represent are market leaders in their product segment.
Corrugating Rolls
OWI has been very fortunate to have enjoyed the patronage of the most discerning market leaders in the business of Corrugated Packaging in the country.
OWI Technical Support Division offers: Process Controls Improvement in Process Specially additives & coatings Project Consultancy
Semi Auto Gluing Machine
Crew Training Custom Retrofit Projects
Technical Support Division Headed by Director Technical:
Archie Brown Auto Splicer
68 | The Corrugator | July – September 2013
A World of Corrugated Packaging Machinery NEW
Thin - blade slitter scorer
Hand Feed Flatbed Die Cutting
Chain Fed, Printer Slotter & Die Cutter
Lead Edge High Speed Printing Machine
Rotary Creaser & Slotter (RS4) Corrugated Board Production Line
Delhi Office: C-3/16, Rajouri Garden, New Delhi - 110027. INDIA. Tel. +91 11 4668 1488 | Mobile: Harish Madan +91 98736 23248 E-mail: info@oneworldinc.in | harishmadan@gmail.com Regd. Office: A-147, II Floor, Road No. 24, Wagle Industrial Estate, Thane (W), Maharashtra - 400 064. INDIA | Tel.: +91 22 2582 1054 E-mail: bombay@oneworldinc.in | Mobile: Raju Ankola +91 98210 31084
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Cont. from Page 67
AirBond Heat Transfer System With AirBond installed, production over the Double Backer can now run at it’s optimum performance. Heat transfer takes place at the same time allowing moisture to be removed, producing the best quality board. All Heating Plate Pressures can be reduced, due to the AirBond Heat Transfer, giving you great savings on fuel consumption.
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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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Operator HMI Controls
Screen shows when the machine is stopped
Screen shows when the machine is running narrow width paper
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50 YEARS IN THE SERVICE OF CORRUGATED PACKAGING INDUSTRY
ity with v i t c u d e Pro Increas from MICRO es Machin
H
Si
In keeping with the tradition of offering effective solutions to today’s corrugated box manufacturers, MICRO designs and builds machines that are competent, competitive and cost effective. Make Sure It’s
Besides, MICRO machines have stood the test of time for over 40 years and won the trust of box makers in India and abroad. An unmatched testimony to the MICRO reliability.
MICRO MECHANICAL WORKS The Symbol of Quality in Corrugated Machinery
601, Delta, Hiranandani Gardens, Powai, Mumbai - 400 076, INDIA. Tel.: 2570 4446 (3 Lines) l Fax: +91 22 2570 4330 l E-mail: micromec@vsnl.com
74 | The Corrugator | July – September 2013
www.micromechworks.com
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The main operator page shows the pressures being applied at each section. This screen shows the system is configured for 2 heating section and a traction section. As an option we can integrate the control of the doctor roll to glue roll gap. This will modulate with speed to the curve set by the operator. These settings can also be saved for recall at a later time.
Screen shows when the machine is running over X width
Screen shows when the machine is running over Y width X and Y dimensions are machine width dependant
Two Heating and Traction Section Configuration with Glue Gap Modulation.
The main operator page shows the pressures being applied at each section. This screen shows the system is configured for 3 heating section and a traction section.
The main operator page shows the pressures being applied at each section. This screen shows the system is configured for 2 heating section and a traction section.
The system can be ran in Manual, semi automatic or fully automatic with remote computer job transfer. At order change the system will automatically change the settings to a job number which was created earlier. Every time the order is ran these settings can also be altered if need be.
As an option we can integrate the control of the doctor roll to glue roll gap. This will modulate with speed to the curve set by the operator. These settings can also be saved for recall at a later time.
Three Heating Section Steam Control
Two Heating and Traction Section Configuration with Glue Gap Modulation. Cont. on Page 79 The Corrugator | July – September 2013 | 75
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76 | The Corrugator | July – September 2013
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Service Centre in Mumbai with 2 Chinese Engineers
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Cont. from Page 75 The glue curve page shows the set points entered by the operator. The red dot is the actual position of the glue gap relative to speed. These gaps can be altered and saved whilst the machine is running. When the gaps are saved the next time the job number is ran it will automatically change the glue curve. Making it easier for the operator to run the machine and giving more consistent board quality.
Refurbished 16 heater plate 2.5M double backer retrofitted with our AirBond Heat Transfer System
Glue Curve Set Up Screen
Feedback from Customer Following a further successful installation, we have worked with our customer to reduce steam and starch consumptions. Before the installation, the customer had three Heating Sections controlled by pressure on the heating section. In conjunction with the AirBond the pressure was reduced as follows: B Flute Before Installation After Installation
Section 1 6 Bar 3 Bar
Section 2 Section 3 8 Bar 6 Bar 3 Bar 3 Bar
B Flute Before Installation After Installation
Section 1 6 Bar 3 Bar
Section 2 Section 3 8 Bar 6 Bar 3 Bar 3 Bar
What Does AirBond mean to You Either by installing a full system or replacing sections of existing heat transfer systems, AirBond is going to give you the following immediate results / benefits: l Optimum Control Of Heat Transfer from your Double
Backer l Reduced Operating Costs through reduction in both
energy and starch. l Increased Board Quality and Reduction in Waste Produced. l Higher Performance from Lighter Weight Papers. l Reduced length Double Facers. l Immediate conversion capability, Can Be Fitted to All
Double Backers l Greater efficiency when running all flute and grade
combinations. l Greatly reduced maintenance. Only High Grade Materials
are used. l 100% Backup Service and Support from Production and
Field Service Engineers of JKSP Services with many Years of Experience in Corrugating, Converting and Materials Handling Systems Worldwide. l The shortest Return on Investment (ROI) of any system
offered.
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Industry News Corrugated Packaging Alliance responds to IFCO Life Cycle Analysis Corrugated Packaging Alliance (CPA) Executive Director Dennis Colley issued the following statement regarding the Life Cycle Analysis (LCA) recently released by IFCO. Performed by Franklin Associates, the LCA compares Returnable Plastic Containers (RPCs) with Corrugated Containers (CCs).
“I applaud IFCO for sponsoring a study to compare RPCs with CCs. However, there are assumptions used in the study that don’t accurately reflect the corrugated market. These discrepancies influence the study in favor of RPCs. CPA has also been working on a comparative LCA to be released later this year. The study will contain accurate
IIP moots packaging solution for safer midday meal scheme Dr. Purandeswari, Union Minister of State for Commerce and Industry addressing the National Conference on Global Trends in Packaging of Food , Pharmaceuticals and Bulk Drugs in Hyderabad
corrugated container and container board mill data, along with RPC data as reported by IFCO. The CPA study examines industry-wide corrugated data rather than data from one individual company and will include all ten commonly-used ISO certified environmental indicators instead of picking and choosing indicators that bias one system over another.” Colley added that “As produce retailers review these studies, there are other continuous improvement initiatives that deserve consideration. The corrugated industry has a long history of responsible environmental stewardship: l Corrugated containers are made from a renewable resource — trees. Today, the United States has 20 percent more trees than it did on the first Earth Day celebration more than 40 years ago. l Sustainable Forestry Initiative participants plant 1.7 million new trees every day, contributing to the long-term viability of North American
forests, preserving wildlife habitats, sequestering carbon dioxide and offsetting greenhouse gas emissions. l Forest products facilities produce 70 percent of the renewable biomass energy used by the entire manufacturing sector. l 91 percent of corrugated containers were recovered for recycling in 2011, as recently reported by EPA. l AF&PA members are committed to reducing water use in their pulp and paper mills by 12 percent by 2020. Colley concluded, “The CPA, its sponsors and member companies recognize the importance of balancing good environmental science with creating efficiencies in the produce supply chain. In partnership with produce growers and shippers, corrugated manufacturers will continue to seek optimal performance in the delivery of produce from field to table.”
“We took it up as our own R&D project. We were surprised by the way food was being prepared and distributed. We are going to make a proposal. We will develop a prototype,” IIP Director N C Saha said here on the sidelines of a national seminar on
The Indian Institute of Packaging (IIP) is exploring the possibility of lending its expertise to the implementation of midday meal scheme in the country to ensure that quality food is served to the children. “We took the initiative last year. In Maharashtra and West Bengal, we did a survey at 35 centres which are implementing the midday meal project.
‘global trends in packaging of food, pharmaceuticals and bulk drugs’. He said various designs are being explored like developing a “collapsible and returnable” package which children can carry home and bring back. Dr. Purandeswari, who inaugurated the seminar, said it was going to be a huge challenge given the nature of the project.
Dr. Purandeswari, Union Minister of State for Commerce and Industry, at the Inaugural function. Seen with her is Mr. N. C. Shah, IIP Director
She, however, said that the proposal was still in its preliminary stage. Cont. on Page 88
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Cont. from Page 85
Pyramid Packaging hosts open house to showcase the Bobst Quatro Pyramid Packaging, part of Horizon Packs hosted an open house to showcase the FFG618 Quatro along with a range of corrugation capabilities at their factory in Kanakpura near Bengaluru. The full day open house which included a live machine demonstration; also provided technical presentations by the Bobst team. The event was attended by the top names from the Indian corrugation and folding cartons industry. Kirit Modi, managing director of Horizon Packs, thanked the Bobst India team for a smooth installation of the FFG618 Quatro in February 2013. In his speech to an audience of 40 delegates, he outlined five key trends in the brown box segment. The first trend was the importance of an automated packing line and a highend equipment. The second trend, Modi highlighted was the the boost to the fruits and vegetables segment; and multicolour graphics. The third trend was the entry of modern retail and the therefore multicolour and photorealistic images. The fourth trend is the entry of modern retail and the new possibilities for printing on the brown outer surfaces. Modi stated the advent of international brands in the converting segment meant financial incentives and further development of the Indian corrugation industry. This would raise the quality bar. And finally, he said customers are seeking light-weight boxes with the highest quality at attractive prices for the growing market for large-sized packages and logistic display. The FFG618 installed at Pyramid seems to be poised to take on some of these challenges. It is a four colour flexo machine, which is also capable of slitting, scoring, folding, gluing and rotary die-cutting inline. It also has a posilock die-cut system and specialises in short orders.
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According to Subhasis Roy, business director, Bobst SA, said, “85% of the RSC (regular slotted container) boxes in the corrugation segment tend to have single or two colours.” But the samples on display during the open house indicate the possibilities for four colour jobs. This, as Roy commented is ideal for the beverage and vegetable oil industry. Today, in India, this is being rendered by the offset litho laminated route. Roy said, “But these kinds of jobs could be printed on a FFG route or offline post-print flexo route like the Bobst Flexo 160 Vision and the quality is almost comparable to offset.”
to adopt better technology and automation in the process.
During the live demonstration, the machine was running at 20,000 boxes per hour. But the machine can produce RSC boxes upto 26,000 boxes per hour. FFG618 is a 1.8 metre width machine and can handle quick changeovers upto 12 in one shift.
The evening concluded with some of the top names in packaging sharing their views. Pankaj Shah of Supack said, he was impressed with what he saw. He stated, “The machine was running smoothly, the board was flat, the speed was 20,000 boxes per hour which could be increased. Plus there was no fish-tails and well-designed for the operators.”
Roy added, “There is pressure on the corrugated industry by the end users to delivery good quality and better strength board and glued boxes and better graphics. With the advent of JIT and short order changes and automatic case maker/ case formers coming in the corrugated board industry, this will further push convertors
Roy seemed to suggest that the converters need to think out of the “brown box”. He stressed on the cost component of the kit; as well as the price performance balance. In his presentation, he touched upto a cost analysis study conducted with Indian converters and Indian raw materials. He stated Bobst was keen to co-operate with Indian converters to better understand, “pricing structures, payback, monthly EMI, per unit cost, funding sources and finance schemes.”
Packaging consultant, Anshuman Roy concluded his talk by stating, “The packaging must sell more than what it costs.” This is what the FFG618 Quatro at Pyramid Packaging seems to be doing. Cont. on Page 97 The Corrugator | July – September 2013 | 89
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Stitcher
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Cont. from Page 89
Stora Enso expands renewable packaging business to Pakistan Stora Enso has signed an agreement to establish a joint venture called Bulleh Shah Packaging (Private) Limited with Packages Ltd. of Pakistan. Stora Enso’s initial shareholding will be 35% with a commitment to increase the shareholding at the agreed value to 50% at a later stage subject to certain conditions being met. The joint venture will include the operations of the Kasur mill and Karachi plant currently owned by Packages Ltd. The joint venture will to a large extent provide packaging products to key local and international customers in the fastgrowing Pakistani market. The joint venture will employ about 950 people and its sales are forecast to be USD 130 million (EUR 99 million) in 2012. The agreed value for 100% of the jointventure company is approximately USD 108 million (EUR 83 million) on a cash and debt free basis. The total consideration can be up to USD 125 million (EUR 96 million), including an additional maximum performance compensation based on the financial results of the second half of 2012 and the first half of 2013. As part of the agreement, both parties are committed to a substantial USD 135 million (EUR 103 million) investment programme during 2013 and 2014 to develop the business further. The joint venture is EPS accretive and will over time after the new investments exceed Stora Enso’s ROCE target of 13%.
“This is an example of Stora Enso’s investments in value-creating growth markets. The Pakistani market, with growing demand for packaging products and paperboard, offers an attractive growth opportunity for us and the joint venture will enable us to increase our capability to serve our key customers,” says Mats Nordlander, Executive Vice President, Renewable Packaging Business Area. The joint-venture transaction is expected to be completed during the first quarter of 2013, subject to competition and regulatory approval and other customary transaction conditions. Packages Ltd. is the largest packaging and board producer and converter in Pakistan. It has 3 000 employees. The main assets are located in Lahore and Kasur in the province of Punjab. The market capitalisation of Packages Ltd. is USD 86 million and the shares are listed on the Karachi, Islamabad and Lahore stock exchanges. Packages Ltd. has a long tradition of working with key local and international companies. Stora Enso already has a 6.4% shareholding in Packages Ltd.
Stora Enso is the global rethinker of the paper, biomaterials, wood product and packaging industry. They always rethink the old and expand to the new to offer their customers innovative solutions based on renewable materials. Stora Enso employs some 30000 people worldwide.
SIES School of Packaging, Navi Mumbai gets Dr. Rangaprasad as the New Director Dr. R. Rangaprasad has taken over as Director at SIES School of Packaging, Navi Mumbai.
His is a chemical technologist by training from UICT, Mumbai and holds, B.Sc. (Chemistry), B.Sc. (Tech.), M.Sc. (Tech) and Ph.D. (Tech). Dr. R. Rangaprasad has served as visiting faculty from industry at UICT, Mumbai; Amrita Vishwavidyapeetam, Coimbatore, Nirma Institute.
Kasuri Paper Mill in Pakistan
He was honored as UDCT -IPI Diamond Jubilee Visiting Professor in Polymer Processing. He has also conducted training & knowledge workshops at leading FMCG companies in the area of design of polyolefin materials for packaging sector. Dr. Rangaprasad teaching interests are in intermaterial and interpolymer competition for end use applications in packaging. He is also committed to developing learning modules in the area of packaging material science and technology.
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Inauguration of J. S. Machine Factory at Indore, India. From August 22-28, J. S. Machine India Pvt. Ltd Inaugural celebrations were held at J. S. Machine India Factory, Indore, India. It is the first overseas factory of J.S. Machine in the world which is dedicated for Corrugating Rolls (including rolls repairing), selling of spare parts and prompt service. With this, J.S. Machine hopes to reduce costs and improves efficiency for their customers. The Inauguration was attended by some of the prominent members of FCBM.
Mr. Olivier Li, General Manager of J. S. Machine addressing at Inauguration
From left to right: Mr. Joy Tian; Mr Adam Wang, Manager of J.S. Machine India Branch; Mr. Mike Sun
Bobst India initiates Bobst School of Converting Bobst India has started the Bobst School of Converting in Pune, which offers certificate programme which has commenced from 1 May, 2013 with four candidates on its roll for the first batch. To begin with, Bobst India has started the three month folder-gluer machine operator training course in Pune. This is the first certificate course from Bobst Vocational training center.” “The customers of Bobst can sponsor their employees for this course as well as fresh ITI pass candidates. Discussions with various customers highlighted the need for a trained operator to the BOBST machines at the optimum level and getting a person to run it is difficult for first time machine buyer as well as repeat customers. Keeping this gap in mind Bobst designed a course curriculum which will train an ITI pass out to run their folder gluer very efficiently right after it is installed. Cont. on Page 103 The Corrugator | July – September 2013 | 99
Turnkey Engineering Solutions Vacuum absorption fingerless type high speed single facer machine group
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High speed PLC based fully auto 4 color printer slotter with rotary die cutting, lead edge feeding system: in ilable d, a v a Also dge Fee in a E Lead ed and ch ut r fe itho Kicke ystems w s u s vario feed n i PLC zes. si
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We offer high quality 3 ply, 5 ply and 7 ply automatic corrugated paperboard plant with widths from 1400mm upto 2500mm and production speeds from 60 mtrs. upto 250mtrs/ min. in various flute combinations as per customer’s choice. Contact: Mr. Randeep Sharma | +91 98672 08454 A-275, TTC-MIDC Mahape, P. O. Ghansoli, Navi Mumbai - 400 701 (India) Telefax: +91 22 2778 0209, 2778 0212 E-mail : cartonmachineries@gmail.com • flotech2002@yahoo.co.in www.cartonmachineriesindia.com
to the Corrugated Packaging Industry Our excellent infrastructure available at the Navi Mumbai facility, an emphasis to offer only good quality machines to our customers backed up by vast experienced technical support team to deliver efficient and prompt after sales service and maintaining adequate essential spares for all machines that we offer, helps us in serving our domestic and international customers in a better way.
Semi Auto Flute Laminating Machine
Other products: Auto and semi auto folder gluer machine. Auto and semi auto flute laminator machine. Semi auto 1- piece and 2-piece box stitching machine. Lead edge feed, kicker feed and chain feed rotary slotting, creasing and slitting machine. l Lead edge feed, kicker feed and chain feed rotary die cutting machine. l Thin blade slitter, scorer machine. l Pasting machine. l Platen punching Machines. l Sheet pressing machine. l Manual stitching machine. l Auto bundling machine. l Heating systems for automatic paperboard production lines and single facers. l l l l
Semi Auto Folder Gluer Machine
Finger Type Single Facer
Semi auto box stitching machine (Single piece & Two piece)
102 | The Corrugator | July – September 2013
Cont. From Page 99
Sree Sakthi Paper to increase capacity Sree Sakthi Paper is proposing to increase its kraft paper manufacturing capacity from 70 tpd to 170 tpd. The company’s existing kraft paper unit, located at Edayar industrial development area, has a capacity of 20,000 tpa. It is proposed to install a new machinery to produce 100 tpd kraft paper at the existing location. It is expected that the annual
production will go up by 35,000 mt. The current installed capacity in both the units (kraft paper and duplex boards) put together is 40,800 tonnes per annum. This is likely to go up to 75,800 tpa after the completion of expansion. A power plant of 2 mw is also proposed to be set up by the company, which will be fully used for generation of requisite power and steam for the entire production capacity of 56,600 mt.
The expansion of kraft paper will cost Rs 12 crore while the cost of cogeneration unit is estimated at Rs 7 crore. The company is coming out with an IPO to fund these projects. It hopes to start civil works of the project in January 2006, which will be completed by September 2006. Both the kraft paper units are expected to go on stream by December 2006.
INNOVATION IN CORRUGATED “Emergency Toilet- Biodegradable” Made out of Corrugated Board Shortlisted For National Fair
Dharmendra V. Pandya Viva Packaging Products, Ahmedabad
The innovative corrugated products developed by Mr. Dharmendra Pandya of VIVA PACKAGING PRODUCTS, Ahmedabad “EMERGENCY TOILETBIODEGRADABLE” made out of corrugated board has been shortlisted as one of 47 out of 189 innovative entries of all categories for the western region fair organised by CII, Department of Science & Technology-Government of India & Agilent Technologies on 24th September 2013 at IIT Powai, Mumbai. A panel of jury members has further shortlisted the project “EMERGENCY
TOILET- BIODEGRADABLE” including other 10 top innovation out of 47 presented from the regional fair for participation at the National Fair on 17th October 2013 at the Lalit, New Delhi. INDIA INNOVATION INITIATIVE-i3
Jointly promoted by, Department of Science and Technology (DST), Government of India and Confederation of Indian Industry (CII), Agilent Technologies aims to support Innovation Ecosystem in the country by sensitizing, encouraging and rewarding innovators, and by facilitating commercialization and incubation support for potential innovations.
Mr. Corrugated shortlisted for prestigious marketing award Great News: Mr Corrugated has been shortlisted for Trade Media campaign of the year in the Grocer Marketing, Advertising & PR Awards. The Grocer is the main grocery trade magazine in the UK. Take a look at the shortlist here http://www.gramia.co.uk/page/2013_shortlist. html. There were 94 entries for the Trade Media category alone, so this is a strong achievement by Mr Corrugated! The Awards ceremony will be held on the 31st October at the London Film Museum. Go Mr C!
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Products Profile CorruMax® The New Profile from BHS
transported more efficiently and customers confirm good board strength and higher productivity when it comes to transportation and internal manufacturing processes.
People all over the globe are striving for more efficient energy and raw material utilisation. The paper industry has already responded to this need. Using new paper machines equipped with state-of-theart technology, it is already possible to efficiently produce medium papers with grammages of 60 to 90 g/m². In recent years, these papers have achieved a considerable market share in Europe and Asia. With these new papers machine and corrugating roll manufacturers are faced with new and complex challenges. BHS Corrugated has embraced these challenges and has, together with European partners from industry and science, developed new corrugator roll profiles which have been introduced successfully into the market over the past few years. Based on scientific examinations using the FEM method and practical tests, the CorruMax®profile series was created. The objective of the developments was the reduction of the medium grammages, taking the following points into consideration: l Consistent high levels of ECT and FCT l BCT strength is maintained for double-
wall board l Height reduction to reduce transportation costs l Avoidance of the Ripple Effect l A product with a high quality look and feel to it
Implementation: Profiles of Corrugating roll profiles have been improved in terms of height, pitch and profile geometry.
With the CorruMax® profile family, BHS Corrugated has set new standards for the processing of light weight medium papers. With over 50 years of experience in machinery and process developments BHS has evolved with the trend in using lighter weight papers. On the basis of ECT, FCT and BCT measurements, it was calculated that it is possible to achieve similar board strength with light 80 g/m² medium papers using CorruMax® profiles as with standard profiles using 90 g/m² medium paper. As can be seen from the following graphs, the theoretical targets were exceeded in practice. Further benefits which were achieved with CorruMax®profiles were: l Improved surface quality and better
printability of the board l Clearly improved runnability on single facers with pressure roll l Lower production costs l Reduction of transportation and stock holding costs Particularly with single wall packaging for beverages and food, excellent printability is achieved which is ideal for products destined for the retail sector where shelf ready packaging is a growth area. Bottles, cans and similar products can be packed and
With a dedicated testing laboratory within their development department, extensive research and examination of temperature distribution and its effect on the CMT strength of medium papers has been done. With lighter papers, moisture content in paper must be conserved and over drying avoided so that strength benefits are maintained. BHS Corrugated has developed experience and solutions for machines in this area to enable BHS Customers to take the optimum CorruMax® profiles for their applications. Apart from the technical values, the general impression of the corrugated board is a crucial factor!
Henkel’s Innovative Aerobond System to Speed up Laminating Process For high-volume applications like laminating, efficient processing is especially important. The innovative Aerobond system from Henkel significantly speeds up laminating processes in the paper and
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woodworking industry while improving their efficiency at the same time. Together with the Hansa Mixer company from Bremen, Henkel has developed a system solution for the aeration of laminating adhesives that enables clean machining even at high production speeds. The Aerobond system incorporates a laminating adhesive and the Glue-Mix unit from Hansa, a device designed to match the specially developed Henkel adhesive, which introduces controlled quantities of air into the adhesive and distributes it optimally over the substrate surface. This application considerably increases the volume of the adhesive, so that significantly less adhesive is used for the same laminating area.
Aerated adhesives for best results The system also has a substantial impact on conditioning times. Conventional adhesive blends typically have a high moisture content, requiring conditioning times of up to 24 hours, which can slow down entire production lines. With Aerobond, the volume of air in the mix reduces the moisture content significantly, cutting lengthy conditioning times to just a few hours while ensuring better bonding.
The Aerobond system is currently being used globally in sheet-to-sheet lamination, inline lamination and in the wood industry. It is easy to operate, robust and highly reliable. Henkel developed the system jointly with Hansa Mixer and offers it exclusively to its own customers. Henkel operates worldwide with leading brands and technologies in three business areas: Laundry & Home Care, Cosmetics/ Toiletries and Adhesive Technologies. Founded in 1876, Henkel holds globally leading market positions both in the consumer and industrial businesses with well-known brands such as Persil, Schwarzkopf and Loctite. Henkel employs more than 47,000 people.
The Revolutionary Rotary Die Cutter – SUN625 66 x 125 fixed Frame – vertically Opening Sun Automation Group’s® SUN625 RDC is the newly designed fixed-frame, conventional board line rotary die-cutter delivering high-speed production of top quality printed and die cut boxes.
smooths the anvil surface every 10,000 cuts and automatically adjusts the anvil direct-drive motor speed for automated compensation. All of this is done without interrupting production and without operator engagement.
Select Yom Blade System The SUN625 can be customized with two different ink metering systems: the ColorMaster single blade system or our newly developed Accuprint chambered system. Both offer converters flexibility, automated wash-up, quick blade changes, and an integrated control system. Our experts can help you choose the right ink metering system for your market.
Digital Harmonic Register Printing plate position and cutting die position are made precisely with SUN’s Digital Harmonic Registration System. Absolute position can be adjusted and controlled to 0.001 inch (0.0025mm) Quick and Easy Plate Change 40 seconds after the last board has run, the vacuum
The process decreases the moisture content over the bonding area, thus improving flatness. The aerated adhesive is better able to compensate for unevenness across the substrate surface. This improves the initial bond strength and minimizes areas with insufficient adhesion. The Aerobond system is easy to use, offers greater flexibility in production processes, reduces downtimes for cleaning of laminating lines, and allows in-line production. Modern adhesive application units normally use counter-rotating roller systems that apply the adhesive directly to different substrates, such as open or closed flute corrugated board as well as solid board. Printed sheet material is laminated to the substrate in this work step. Aerobond system exclusively for Henkel customers
Micro Grind Die Cut Accuracy Control System Our proprietary die cut system improves box dimension consistency, scoring quality, and scrap management. The fullwidth tungsten carbide grinding roll
Transfer unite are up, and the print plates can be easily changed for the next job. The SUN625’s walk-in architecture provides unobstructed access for machine operators. Cont. on Page 111
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Cont. from Page 107 ZipLink® is an innovative belt range which is specially designed to offer benefits in a variety of different industries. Quick and simple installation or repair help to lower costs and reduce downtime. The design allows for repair or replacement of just small sections of the belt.
SunTrac. Vacuum Transfer SunTrac Vacuum Transfer provides complete sheet control and delivers exceptional print-to-print registration. A typical 6 color machine can run with as little as 1/32 trap (0.75mm) at top speed. In addition, the separation between print cylinders provides extra drying time. No pull bands are ever needed and print impression can be adjusted by 0.001 (0.0025mm)
Lead Edge Feeder SUN’s patented extended stroke feeding system uses four wheel shafts on the SUN625 to increase sheet control and substrate flexibility. The result? Better registration, reduced feed roll crush, and the ability to handle heavier pile heights.
Ammeraal Beltech Offers Belts that joint instantly Ammeraal Beltech is a leading manufacturer of process and conveyor belting with an establishedreputation for developing innovative solutions for belting applications.
All belts can work in humid working conditions upto 120ºC. Ammeraal Beltech has developed a complete range of elastomer covers to meet the specific demands of the industry. All belts can work in humid working conditions up to 120°C. Natural rubber Nitrile covers provide the perfect grip no matter the type of board. Special carboxylate rubber is used to achieve the maximum abrasion resistance for the longest life possible. Ziplink, ideal for whatever application where belt replacement time is an issue.
Here comes the Beer cooler pack The easy to open one piece design splays open to create a water resistant ice bucket, providing a secondary use for the beer case that is ideal for sharing occasions. Developed in conjunction with CRP Print & Packaging, one of Europe’s leading independent specialist packaging groups, the 18 bottle ‘cooler box’ was launched into retailers in Spring. The development of this innovative pack which uses specialised water resistant papers, required an extended product development phase including technical and design expertise. The inside of the pack has a laminated waterproof barrier and is externally litho printed with an aqueous varnish. One of the key challenges to overcome in designing this pack was to ensure the pack could be 100% recyclable. The consumer interaction is intuitive with the case opening to reveal a void around the product for filling with ice – says the company sales Manager
Easy replacement of the complete belt or of small sections in the event of damage. You can achieve considerable cost savings: easy to use tooling kit; no specialised outside fitters required.
Working closely with OEM’s and end users Ammeraal Beltech have developed a range of ZipLink® belts: a special design link fabric in combination with top covers giving superior performance. Main benefit is the striking increase of your production time.
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Clariant launches truly pfoa-free cartaguard khi for greaseproof and safer food packaging papers
Hence, Tereos Syral help you to achieve high productivity and energy efficiency and meet continuously increasing requirements for quality.
l Truly PFOA-free grease repellent for
food packaging paper l Supports use of healthier, eco-friendlier
Impregnating agent Cartaguard KHI is easy to apply and does not affect the printing or adhesive properties of paper. (Photo: Clariant)
Tereos Syral is the third largest starch producer in Europe with production Facilities in Belgium, France, Spain and Italy. Tereos Syral application centre in Marckolsheim develops new adhesive concepts.
food packaging by brand owner l Clariant innovation fulfils requirements
for both effective and safer food packaging Clariant, a world leader in specialty chemicals, introduces Cartaguard® KHI – a revolutionary, high-performance and totally PFOA-free grease resistant additive for effective and safer grease-resistant food papers and board.
safer grease resistant packaging to replace traditional plastics and paper-plastic combinations. The new impregnating agent also brings production advantages to the paper mill. It is easy to process because it generates hardly any foam during paper production and does not affect either the adhesive or printing properties of the paper.
Mitsubishi Introducing the 65J Glue Machine New Cartaguard KHI supports the trend toward more eco-friendly solutions for hand-held, ready-to-eat foods such as burgers, pizza, pastries and confectionary. Unlike some other existing fluorine technologies, it makes paper grease resistant without releasing impurities into the packaging. It penetrates into the paper or board and attaches to each fiber to create a protective surface that protects hands and clothing from grease. As a result, manufacturers can produce viable,
Cartaguard KHI: truly PFOA-free grease resistance for food papers and board. (Photos: Clariant)
Cartaguard KHI molecules on the fiber’s surface prevent grease drops from soaking the paper. (Photo: Clariant)
Cartaguard KHI is already approved for food contact applications by the German Federal Institute for Risk Evaluation (BfR) and the US American regulatory agency FDA, and meets the stringent requirements for food service packaging.
Starch Glue Concepts for Corrugated Boards Tereos Syral’s team of experts, together with corrugated board producers and machinery suppliers, have developed efficient and tailor-made solutions to adhesive problems. Their starches have been designed to enhance product performance in a costefficient way for the latest corrugators. They develop tailor –made starch glue concepts to fit your specific production requirements.
Mitsubishi has recently Introduced a 65J Glue Machine The fallowing are the main feature of the Machine: l 450m/min production speed l Stable glue thickness l Designed for light and heavy papers l Adjustment free operation, easy
maintenance, high quality board
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Asitrade MASTERFLUTE Litho-laminator The latest generation of Asitrade high performance sheet to web laminator with a performance of maximum 210 m/min or 11’000 sheets/hour. The laminator can be ideally combined with their improved Module Facer MF 300 (250 m/min). MASTERFLUTE includes a progressive sheet alignment system Power Aligner WITHOUT front stop and mechanical side lay, sensing the sheet edges with optical sensors eliminating mechanical stops and risks of sheet damage.
Keep the strength of the corrugated with The Innovative EMBA 175 QS Ultima. The EMBA 175 QS Ultima’. The progressive evolution of the unique UltiinaTM technology platform.
The innovative and patented EMBA NonCrush Converting” technology eliminates nip points, preserving the geometry and strength of the corrugated profile throughout the entire converting process, creating significant savings in paper cost with higher FJCT values for a much stronger product, and exciting productivity. The intelligent Ultima technical platform is the result of focused collaboration with cus¬tomers, who recognize that high machine speed, optimized precision and low, predictable main¬tenance costs are key requirements for any new Flexo Folder Gluer machine. Ultima™ platform offers “easy to run and easy to learn” features for machine operators and a modular development environment for designers, making the
It achieves a consistent overlap resulting in more accurate die cutting and minimized waste. The new design emphasizes the new era of outstanding High Performance Laminators, which takes in account increased noise limitations as well as low energy consumption. MASTERFLUTE is ideal to serve mature markets with high volumes and ultra precise tolerances. Even for very large formats and very low base weights high production efficiency can be guaranteed.
EMBA 175 QS Ultima™ upgrade compatible throughout its entire lifetime. EMBA patented Non-Crush Converting technology preserves the geometry and strength of the corrugated profile for optimum box performance and significant savings in material costs.
Michelman introduces new water-repellent coating solution HydraBan® 420 is a versatile new water repellent coating from Michelman used by converters of paper and corrugated. It is an economical and easy to run coating with or without dilution. It is FDA-compliant for direct food contact, repulpable and recyclable.
EMBA’s World first Non-crush Converting” A technology, with the unique Ultima’ feed unit and the acknowledged Quick-Set’ feature, makes the EMBA 175 OS Ultima’ and EMBA 245 OS Ultima’ unbeatable. Utilizing a new chemistry, Michelman has formulated HydraBan 420 to minimize or eliminate foaming and separation issues. The new coating exhibits excellent water beading and printability and is cold set gluable with most adhesives. HydraBan 420 can be applied in-line on the corrugator from the wet or dry end, with a rod or blade coater, or offline. It can also be applied by
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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
21:99
Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Moisture Content in Paper and paper board.
22:00
Technical Information Booklet – Industry Survey – 1999
R-1:00 Corrugated Box manufacturers’ Practical Standards – Box Dimensions, styles, Mfrs. Joints
23:02 24:02
25:02 26:03 27:03 28:03 29:04 30:04 31:05 32:05 33:05 34:06 35:06 36:06 37:06 38:07 39:07 40:07 41:08 42:10 43:11 44:11 45:12 46:12
Technical Information Booklet – Industry Survey – 2001 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 Project Report (Condensed Version) Technical Information Booklet – Industry Survey – 2002 Proceedings – Technical Sessions of 31st Conference 2002, Mumbai Proceedings – Technical Sessions of 30th Conference 2001, Chennai Corrugated Box manufacturers’ Practical Standards – Standard Test Method for Thickness of Board Technical Information Booklet – Industry Survey – 2003 Proceedings – Technical Sessions of 32nd Conference 2003 Proceedings – Technical Sessions of 33rd Conference 2004 Technical Information Booklet – Industry Survey – 2004 Proceedings – Technical Sessions of 34th Conference 2005, Bangalore Technical Information Booklet – Industry Survey – 2005 Technical Information Booklet – Units of Measurement and Conversion Factor Technical Information Booklet – International Rules for Corrugated Board and Cases Proceedings – Technical Sessions of 35th Conference 2006 Technical Information Booklet – Restricted Heavy Metals Specification in packaging Material Technical Information Booklet – Guidelines for Designing Heat Transfer System using Heat Transfer Fluids Proceedings – Technical Sessions of 36th Conference 2007 Proceedings – Technical Sessions of 38th Conference 2009 Proceedings – Technical Sessions of 39th Conference 2010 – Interactive DVD Technical Information Booklet – Industry Survey – 2010 Proceedings – Technical Sessions of Tec 40th Conference 2011 – Interactive DVD hnic al In Boo forma tion kle t Scoring allowances and Blank size FCBM
46:1
2
Scor
FOR
owan
ces
For further details contact:
Federation of corrugated box mfrs. of India Tel.: +91 22 2850 0687, E-mail: adminfcbm.org, www.fcbm.org
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PRIVA TE CIR
CULAT
ing all
Fede Man ration of ufac ture Corrug rs of at Indi ed Box a
and
Blan
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ONLY
Forthcoming Events 17-19 October 2013
24-27 October 2013
16-18 January 2014
INDPACK 2014 to showcase state-of-the-art packaging technology 17-18-19 October 2013 at Pragati Maidan, New Delhi IndiaCorr Expo 2013 is your gateway to complete Indian corrugated manufacturing industry. The event features the latest and most innovative corrugated equipment and technology. Over 350 brands from India as well as international countries including China, Japan, Taiwan, Italy, France, Canada, Germany, UK and US will be showcased. You would see from corrugated board making machines to corrugated box making machines, testing equipments to adhesives, printing machines, kraft paper, tapes & other accessories.
Paperex – ‘11th International Exhibition & Conference on Pulp & Paper Industry’ World’s renowned business platform in form of international exhibition and conference for the Pulp, Paper and allied industries. Presence of more than 500 leading exhibitors from more than 40 Countries and expecting 30,000 trade visitor from around the globe.
After the overwhelming success of recent two editions of INDPACK held at Hyderabad & Guwahati respectively, the Indian Institute of Packaging (IIP), premier institute in the country and an autonomous body working under Ministry of Commerce & Industry, Government of India will be organising its 16th edition of national packaging exhibition & conference “INDPACK 2014” from January 16-18, 2014. This three-day mega event will be held at the Hall no. 7, Pragati Maidan, New Delhi. For more details : www.iip-in.com
5-7 November, 2013
8-14 May, 2014
16-23 October 2013 In Asia your consumer base is seeing an increase in living standards, they are willing to buy more of your high end products, but as the labor costs are increasing rapidly you must be proactive and plan accordingly. With over 3,000 exhibitors, K in 2013 will again be the undisputed flagship event of the industry and hence the ideal business and contact platform for inspirational ideas and forward-looking decisions. On over 168,000 sqm of net exhibition space in 19 exhibition halls, a comprehensive and clearly structured offering awaits you.
3-6 December, 2013
Shanghai
Interpack, Dusseldorf, Germany As the world’s leading trade fair, it is the major inspiration for the packaging industry and all related process technologies. 2,700 exhibitors from more than 60 countries will present their latest ideas, innovate concepts and technological visions at interpack - not only in equipment and machinery for packaging and processing, but also in production tools for packaging materials, materials themselves, and services for the entire industry.
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