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. : 800 Sq. Ft. For machine shop for Board Making.: 5,000 " " For machine shop for Box making. : 7,000 " " For Godowns or storage etc. : 10,000 " " _______________ Total. : 22,800 " " ________________ 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".

Rs.7, 50,000/Rs.2, 50,000/Rs.3, 50,000/Rs.1, 50,000/Rs.2, 50,000/Rs.1, 25,000/_________________ Rs.18, 75,000 _________________

Total.

BOX MAKING UNIT: 1. Die Cutting & Creasing Machine medium size say 32"x42" or as required. Rs.4, 75,000/2. Four Bar Rotary Cutting & Creasing Machine size - 75". Rs.2, 50,000/3. Eccentric Slotting Machine size 75 Rs.3, 10,000/4. Wire Stitching Machines size -36" & 42" Rs. 45, 000 5. Paprtition Slotting Machine size -42" Rs.1, 10,000/6. Single slotting Machine size - 12" Rs.1, 00,000/7. Vertical Bending Machine size - 48" Rs.3, 10,000 ________________ Total. Rs.16, 00,000/________________

Grand total of both units: POWER REQUIRED AND APPROX COSTS: Total power required for above two Unit is 25 H.P. or 48 Kw. Total costs of power consumption per Year approx. Rs.24 on the Present rates and subject to change. RAW MATERIALS & COSTS: Particulars. Rate P/Kg.

1. Kraft/Media Paper. Rs. 26/2. Glue (Starch). Rs. 3. Silicate. Rs. 4/4. Stitching Wire. Rs. 78/-

Total cost per annum: Rs. 45, 00,000/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. ____ Total. 6. ____ 1. 1. 1. 1. ___ 4. ___ 1. 1. 1. 1. 1. 1. ___ 6. ___ 3. 2. 2. 2. 2. 3. 2. ____ 16. ____

WAGES AND SALARIES: TECHNICAL Skilled. Semi-skilled. Helpers. Supervisor. Total. ADMINISTRATIVE. Salesman. Acctt./Typist. Clrek/storekeeper Peon. Chowkidar. Total. /Month Rs.10, 000/Rs. 5, 000/Rs. 4, 500/Rs. 4, 400/Rs 5, 000/___________ Rs. 28,900/___________ /Annum Rs.1, 20,000/Rs. 60, 000/Rs. 54, 000/Rs 52, 000/Rs 60, 000/___________ Rs.3, 46,800/___________ RATE P.M. Rs.6800/Rs. 4800/Rs. 4500/Rs.10, 000/NOS. TOTAL RS. P.M. 6. 4. 6. 1. ____ 17. ____ Rs.81, 600/Rs.57, 600/Rs.54, 000/Rs. 1, 20,000/_____________ Rs.3, 12,200/_____________

G. TOTAL: Technical + Adminis. + 15% Perquis. = Total. G. TOTAL : 3, 12,200 + 3, 46,800 + 98, 850 = 7, 57,850/-

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.40, 00,000/Furnitures & Office equipments. Rs.10, 00,000/________________ Total. Rs.50, 00,000/________________ RECURRING EXPENDITURES FOR 30 DAYS: Raw Materials. Rs.15, 00,000/Salary and Wages. Rs.1, 40,000/Travelling, Cinveyance, Packing, Freight and postages etc. Rs. 5, 000/Factory Overheads & Misc. expences. Rs.1, 60,000/Electricity and Water. Rs. 20, 000/________________ Total. Rs. 1, 53,25,000/-(PER ANNUM) ________________ TOTAL CAPITAL INVESTMENT: Non-recurring Expences + Recurring Exp. = Rs.2, 03,25,000/ARRANGEMENT OF FUNDS ( FROM BANK OR FINANCIAL INSTITUTION) : Pledge of Machinery ( 75% of value) Rs.22,00,000/Hypothecation ( 70% of processed goods) Rs.53, 00,000/Equity Capital/Promoters contribution. Rs.15, 00,000/________________ G. Total. Rs.90, 00,000/________________ 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.4, 00,000/Equity capital 25%. Rs.1, 32,000/Total Promoters contribution will be Rs.1,50,000/COST OF MANUFACTURING PER ANNUM: Rent of Building @ Rs. ---p/month. Rs. Total recurring exp. for one year. Rs.1, 84,00,000/Dep. on Plant & Machinery @ 25%. Rs. 10 ,00,000/Depriciation of Office equipment @ 20% Rs. 2, 00,000/________________ Total Rs. 18, 52,00,000/________________

SALES PROCEEDS (ANNUALY): By the sale of ..Kgs. of Sheets from which Boxes are manufactured sold @ Rs per kg. Rs.20, 00,000/LESS costs of manufacture. Rs.1, 70, 00,000/________________ Gross Profit. Rs. 30, 00,000/LESS Interest of Term Loan ( 20% on Rs..) Rs. 5, 00,000/________________ NET PROFIT. Rs. 25, 00,000/________________ 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.