GUIDELINES TO MAKE PROJECT REPORT FOR PAPER CORRUGATED
BOARD AND BOX MAKING PLANT:
BOARD AND BOX MANUFACTURING PROCESS:
Corrugated Board is made with a Corrugated Sheet of paper attached
to the facing of flat paper, usually Kraft/Media paper by adhesive.
In India, it is mostly produced over a SINGLE FACER MACHINE. Here
two paper reels are run together. One layer of paper becomes
corrugated after passing through the heated corrugated rolls and
the other is brought into contact with it after the former having
glued at the trips. Thus both get pasted together and are wound
in rolls. The resulting roll is now known as 2-PLY CORRUGATED BOARD.
By cutting this roll into sheets with either manual BOARD CUTTER
or by on line automatic ROTARY SHEET CUTTER and then gluing the
corrugated side by a SHEET PASTING MACHINE and placing 3RD-PLY
of paper over it, Double face or 3-PLY CORRUGATED BOARD is produced.
This board is kept under pressure in the SHEET PRESSING MACHINE for
some time, for setting of the wet glued sheets to remain straight
and get dried. Similarly board to board is pasted to form thicker
boards i.e. 5-ply, 7-ply, 9-ply or more as required.
MAKING OF BOXES FROM SHEETS:
The process of manufacturing of Boxes or Cartons constitute
five main operations:
1. Slitting or Longitudinal cutting.
2. Creasing.
3. Slotting.
4. Flap or Corner cutting.
5. Stitching.
After passing the sheets through these operations, Boxes or cartons
are ready to use.
Slitting and Creasing operations can simultaneously be carried over
a 4-BAR ROTARY CUTTING AND CREASING MACHINE.
The trimmed and creased sheet is slotted and flap cut on an ECCENTRIC
SLOTTING MACHINE.
Finally it is either stitched over a BOX WIRE STITCHING MACHINE or
glued/taped manually. For partition boxes, the half slotted boards
are used, which can conveniently be produced over a PARTITION SLOTTING
MACHINE.
SPACE REQUIRED (LAND AND BUILDING):
For Office.
: 200 Sq. Ft.
For machine shop for Board Making.: 2,000 " "
For machine shop for Box making. : 2,000 " "
For Godowns or storage etc.
: 1,800 " "
_______________
Total. : 6,000 " "
________________
PLANT AND MACHINERY:
CURRUGATED SHEETS (BOARDS) MAKING UNIT:
1. Single Face Corrugating Machine,
Vertical or Oblique type as required.
Generally, Vertical type - 52" size.
Extra Roll set.
2. On Line Rotary Sheet Cutter - 52" size
3. Manual Sheet Cutter - 52"x62" size.
4. Sheet Pasting Machine- 75" size.
5. Sheet Pressing Machine - 65"x 75".
Total.
Rs. ……………………
Rs. ……………………..
Rs. ……………………..
Rs.……………………..
Rs. …………………….
Rs.………………………
_________________
Rs. …………………....
_________________
BOX MAKING UNIT:
1. Die Cutting & Creasing Machine medium
size say 32"x42" or as required.
2. Four Bar Rotary Cutting & Creasing
Machine size - 75".
3. Eccentric Slotting Machine size – 75”
4. Wire Stitching Machines size -36" & 42"
5. Paprtition Slotting Machine size -42"
6. Single slotting Machine size - 12"
7. Vertical Bending Machine size - 48"
Total.
Rs. …………………….
Rs.…………………….
Rs.……………………..
Rs.……………………..
Rs.…………………….
Rs.……………………..
Rs.………………………
________________
Rs.…………………….
________________
Grand total of both units :
POWER REQUIRED AND APPROX COSTS :
Total power required for above two
unit is ……. H.P. or ………. Kw.
Total costs of power consumtion per
year approx. Rs……………… on the
present rates and subject to change.
RAW MATERIALS & COSTS:
Particulars.
Rate P/Kg. Quantity.
Amount.
1. Kraft/Media Paper. Rs. …….. Kg.………. Rs………..
2. Glue ( Starch).
Rs………. Kg. ……… Rs. ………
3. Silicate.
Rs……… Kg……….. Rs. ……….
4. Stitching Wire.
Rs. ……… Kg………. Rs…………
_______________________________
Rs………. Kgs………. Rs…………
Total. ___________________________________
Total cost per annum : Rs………………………..
PRODUCTION CAPACITY : per 8 hrs. shift.
1. In terms of Corrugated Rolls of …250 RFT. : 60 Rolls.
2. In terms of 3-Ply sheets size 40"x60". 3000 sheets.
3. In terms of weight.
: 1.5 MTS.
4. In terms of Boxes of 15 Cft. cap.
: 4,500 pcs.
MANPOWER REQUIREMENT: Skilled. Semi-Skilled. Helpers. Total.
Corrugating Machine.
Board Cutters.
Pasting Machine.
4-Bar Rotary Ctg.
Eccentric Slotter.
Die-Ctg. & Creasing.
Wire Stitchings.
1.
1.
1.
1.
2.
____
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
___
___
3.
2.
2.
2.
2.
3.
2.
____
Total. 6.
____
4.
___
6.
___
16.
____
WAGES AND SALARIES:
TECHNICAL
RATE P.M.
NOS. TOTAL RS. P.M.
Skilled.
Semi-skilled.
Helpers.
Supervisor.
Rs……….
Rs……….
Rs………..
Rs………..
6.
Rs………………..
4.
Rs. ……………….
6.
Rs………………….
1.
Rs………………….
____
_____________
17.
Rs…………………
____
_____________
Total.
ADMINISTRATIVE.
Salesman.
Acctt./Typist.
Clrek/storekeeper
Peon.
Chowkidar.
Total.
Rs…………..
Rs…………..
Rs…………..
Rs……………
Rs……………
___________
Rs……………..
___________
G. TOTAL: Technical + Adminis. + 15% Perquis. = Total.
SALES REALISATION:
40"x60" x 3000 sheets x 300 days = Production p/year.
40"x60" = 2400 sq. inches.
= 2400x360 divided by 1600 = 540 gm. p/sheet.
= 3000 sheets p/8-hrs. dvd. by 0.540 = 1620 Kg. p/day.
= 1620x300=4.86 Metric Tons Per Annum.
= Sales @ Rs. …………. per kg. approx.
= Rs. …………………..per annum.
INVESTMENT IN CAPITAL EXPENDITURES:
Plant and Machinery.
Rs. …………………….
Furnitures & Office equipments. Rs…………………
________________
Total. Rs. …………………
________________
RECURRING EXPENDITURES FOR 30 DAYS:
Raw Materials.
Rs. ……………………
Salary and Wages.
Rs. …………………..
Travelling, Cinveyance, Packing,
Freight and postages etc.
Rs. ………………….
Factory Overheads & Misc. expences. Rs. ………………….
Electricity and Water.
Rs…………………..
________________
Total. Rs……………………..
________________
TOTAL CAPITAL INVESTMENT:
Non-recurring Expences + Recurring Exp. = Rs…………………..
ARRANGEMENT OF FUNDS ( FROM BANK OR FINANCIAL INSTITUTION) :
Pledge of Machinery ( 75% of value)
Rs…………………
Hypothecation ( 70% of processed goods) Rs. ………………..
________________
Total. Rs. ………………..
Equity Capital/Promoters contribution.
Rs. ………………….
________________
G. Total. Rs. …………………
________________
NOTE: Paper stock for one month extra
worth Rs………………….is required for
efficient and profitable working, which
can be financed as follows:
Pledge with the Bank 75%.
Rs. ………………….
Equity capital 25%.
Rs. ……………………
Total Promoters contribution will be Rs……………………
COST OF MANUFACTURING PER ANNUM:
Rent of Building @ Rs. ………….. p/month. Rs…………………
Total recurring exp. for one year.
Rs. ……………………..
Dep. on Plant & Machinery @ 25%.
Rs. ………………….
Depriciation of Office equipment @ 20% Rs. …………………
________________
Total. Rs. …………………
________________
SALES PROCEEDS (ANNUALY):
By the sale of ……………..Kgs. of Sheets
from which Boxes are manufactured
sold @ Rs………… per kg.
LESS costs of manufacture.
Gross Profit.
LESS Interest of Term Loan
( 20% on Rs………………..)
NET PROFIT.
Rs. ………………….
Rs. …………………
________________
Rs. …………………
Rs. …………………….
________________
Rs. ………………….
________________
HOW TO CALCULATE THE COST OF A BOX:
L = Length of Box.
B = Breadth of Box.
H = Height of Box.
Then 2L + 2B + 2" be length of sheet (let A).
B + H be the width of sheet (let B).
(A + B ) will be the area of sheet used for the said box
and 2" is the margin for stitching/pasting.
Weight/(meter) into square of the sheet = weight of Box.
Cost of Paper + Gum + Wire + Labour + Profit = Sale price.