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The Corrugator | January – March 2013 | 1
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2 | The Corrugator | January – March 2013
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The Corrugator | January – March 2013 | 3
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4 | The Corrugator | January – March 2013
Content Highlights
Federation of Corrugated Box Manufacturers of India 138, Mittal Estate No. 3, M. Vasanji Road, Andheri (East), Mumbai - 400 059.
11 - Creasing Corrugated on Flat Dies
21 – Recognising when to replace cutting dies
E-mail: admin@fcbm.org Website: www.fcbm.org
Please address all correspondence to the Editors at:
29 - Impact of the dimensions
36 - Our experience with semi auto stitcher
Editors
Ashok Vyas Nalanda Packaging Industries, Mumbai ashokpvyas@gmail.com
Harish Madan Securipax, New Delhi Harishmadan@gmail.com
39 - Waste Control in Corrugated Box Plants
55 – Corrugated Industry on the move
Design & Production:
Print Links Bldg. H-4, Flat No. 2 (Lawn side) Jankalyan, Bangur Nagar, Goregaon (West), Mumbai - 400 090. Tel.: 2877 2890 email: printlinks@india.com
59 - FCBM News
63 – Using Color as a measure of 79 - Full colour flexo In-line 87 - We Plan to bring in R&D facilities 93 - Inventory Management 97 - Product Profile
Printed at: Rajesh Printouch, Mumbai
111 - Industry News 73 - Digital printing for
123 - Forthcoming Events
The Corrugator | January – March 2013 | 5
6 | The Corrugator | January – March 2013
the Editors’ page
Ashok Vyas
Harish Madan
The Union Budget for 2013 has generally been welcomed by all, especially since it is aimed at taming the stubborn fiscal deficit. The implications of The Budget on our industry has been painstakingly explained by Mr. Bharat Kedia through an interactive DVD, which was released at the Managing Committee Meeting at Delhi. Mr. Bharat Kedia deserves our appreciation for this novel way of presenting useful information. Our economy which has been sluggish for a while appears to be bouncing back. As per the latest rating by Moody’s, Indian GDP is set for 6.2% growth in 2013 as against 5.1% in 2012 more than what Union Finance Minister had forecast after presenting the Union Budget. ******************* This indeed is good news for the industry. Today India is the sixth largest packaging market worldwide with sales exceeding 24.6 bn USD. The packaging industry is expected to grow 12.3% CAGR during next 4-5 years to become the fourth largest global market. Besides, India will see that increasing awareness regarding clean water, safe food and pharmaceuticals will drive this growth. With increasing retail sector, the concept of track and trace devices
especially for product identification such as 2D Bar- codes, Radio Frequency Identification (RFID) will penetrate aggressively in the packaging industry. ******************* Packaging and Sustainability is an often discussed and debated subject. Sustainability is an ongoing process. It is not just resource conservation or down gauging or using eco-friendly materials, it is a mix of all these together. To achieve sustainability, interaction between stake holders is necessary. Innovations in packaging should be aimed at sustainability and to this effect unified efforts must come from converters, machinery manufacturers and brand owners. Automation is necessary for accelerating growth. Besides automation, the machinery needs to be flexible enough to deliver flexible outputs and serve the consumer in a better way. ******************* In the last quarter, two major exhibitions were held – IndiaPack in Mumbai and PrintPack in Noida. Both showcased latest developments in the field of packaging and printing.
The CCE International Corrugated & Carton Exhibition has just concluded at the Munich Trade Fair Centre in Germany. This dedicated Corrugated and Carton Exhibition opened up new ideas and thoughts that will trigger the growth of our industry. The largest gathering of the global corrugated board manufacturing industry – SinoCorrugated 2013 – will run from April 8 to April11. FCBM will be leading a delegation to this industry event. ******************* The Federation has been vibrant with activities and events organized by Regional Associations. This issue features an article on ‘Creasing Corrugated on Flat Dies’ Also featured is the conversation with Mr. John Luke, Chairman & CEO of MWV – which has big plans for India. The Success Story of a Corrugator in Bhopal is another interesting feature. We do hope you will enjoy and benefit from these useful articles.
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8 | The Corrugator | January – March 2013
President’s Message
It has been 3 months since I assumed the position as FCBM President. It has been a very satisfying 3 month period with activities keeping our Federation vibrant as ever. I had the opportunity of interacting with the members of our Regional Association in Kerala. They had in February organized a Seminar on a novel subject ‘Solar Energy and Corrugated Industry’. Use of alternative sources of energy is an imperative need and is being seriously explored by many organisations. Later on 1st March, I attended the Marathwada Division of WICMA to attend a Seminar on ‘Opportunities for Improvement in Semi Auto Plants’. This again is a subject that calls for our serious attention, since a major percentage of our members continue to operate on Semi Auto Process. I was also welcomed at NICMA office and had the opportunity of interacting with some members of NICMA before attending the 2nd Managing Committee Meeting of our Federation We are all looking forward to attend the Sino Corrugated 2013 which will witness the largest gathering of global corrugated manufacturing industry, I am sure we will all come back with new ideas for growth and productivity in our industry. Like other manufacturing industries, our industry has been going through a slow down. As estimated by global rating agencies, the economy will start being vibrant in 2013. Let us hope this financial year will bring cheer to everyone. FDI in multibrand Retail once implemented will trigger the growth of the packaging industry. We do need to gear up to meet the growing demands for boxes of international standards, as will be required by new global players in Retail, who will be entering the Indian market. Mr. Thomas L Scheneider, President, WPO stated, in a recent article that it is ‘good time to be in the business of packaging’. He furthers outlines that Indian economy is important and will have an even greater impact on the Asian and World markets as well. The growth of affluent middle class in India will create greater demand for packaged goods and will continue to drive packaging towards becoming an even bigger business sector than it already is.
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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
10 | The Corrugator | January – March 2013
Creasing Corrugated on Flat Dies
Jim Buehler Columbus, OH, USA
Introduction In my many visits to carton companies that convert E and F flute corrugated, as well as B and C flute using flat dies, I am often amazed at the lack of consideration given to the creasing process. Many companies seem to base crease rule height and counter size formulas on whatever they have used in the past, or rely on recommendations of an outside diemaker or die supplier. Granted, I have visited carton plants that have studied the issues and adapted their crease rule heights and crease counters to obtain the best results they can achieve. But, even those companies seem to seek assurance that what they are doing is giving them the best possible results. This flat die, corrugated creasing issue led me to compile some information that I have collected from industry sources and carton and display plants that I have visited. I offer it here for your consideration in hopes that you can use the information to overcome the daily creasing difficulties you face. Some of this information is also based on corrugated testing results performed over several months by Harold Squires, now retired from Channel Matrix PLC of Wellingborough, England. The development of small flute corrugated to some extent revolutionized the business of packaging. The material had an effect on paperboard and corrugated diecutters as well as display and point of purchase specialists. Since the smaller flute material can be converted on flat high speed presses as well as traditional corrugated rotary presses, solid board folding carton manufacturers who attempt the smaller flute material and corrugated converters have had to rethink their diecutting methods. Corrugated converters have had to consider issues that solid board diecutters face, and solid board folding carton die cutters have had to learn much about corrugated issues. More corrugated cartons are now being converted on
paperboard into a channel, delamination of the paperboard occurs. In corrugated creasing, a lesser degree of delamination occurs on each liner due to the cushioning of the flutes. If you look closely at a corrugated bead crease and separate the liners from the inner flute, you will find a defined bead crease on each liner. Kevin Carey of Diecutting Information Exchange has defined the elements of a paperboard bead crease in Diagram A. The important point to consider in this diagram is that a paperboard crease will always fold with equal force at the hinge points (4) if the proper selection of crease rule point and height, and the counter width and depth, are compatible with the board specifications. In a corrugated crease, the folding action will take place at the weakest point of the corrugated material. This could occur at either hinge point or directly on the spine, with or without equal pressure. This is why a corrugated crease could appear wavy when sighting down the crease, especially a crease in the direction of the flutes. See Diagram 1.
flatbed presses and the industry is pushing applications to extreme capabilities of B flute, C flute, and even double wall combinations.
Creasing Although developed for paperboard diecutting, creasing matrix can be successfully used to create good creases in corrugated applications. A paperboard folding carton needs a well defined, easily bendable, bead crease in order to pass successfully through a folder/gluer. This is just as true in small flute cartons. When creating a bead crease by forcing
Spine 1 Hinge 2
4
4 3 Bead
2 Levers
Diagram 1 The Corrugator | January – March 2013 | 11
12 | The Corrugator | January – March 2013
E and F flute corrugated can easily be converted with bead crease characteristics and B and C flutes as well with some degree of success. In many cases, B and C flute corrugated will more easily be creased and folded with the “bead” from the channel of the creasing matrix on the outside of the folded carton. We will take a closer look at this, but it is first important to understand the crease rule and creasing matrix formulas to determine appropriate heights and size requirements.
board thickness. This is a starting point, and with most straightforward jobs this formula will work. However, board quality, carton specifications, press and climate conditions all have influence on the quality of the cutting and creasing process.
carton corners or folds in any object should be to the satisfaction of the customer. So, consider these reasons which may determine the side, we cut, and differences in appearance of a 90 or 180° fold when cut from the front or back.
Twice the board thickness crushed plus the rule thickness equals the channel width. See Diagram 3.
Crease rule height
B
When using a counter, the basic formula for determining crease rule height is: Knife height (.937) - Material thickness crushed (.030) = crease rule height [less allowance] (.907) It is important for the diemaker to understand the creasing method used by the diecutter and determine allowances for that method. In the case of corrugated, when a creasing matrix strip is used, an additional allowance needs to be made for steel base matrix and a lesser allowance for a plastic film base matrix. Steel base matrix requires an additional .007 - .008” (.1778mm - .2032mm) and film base .003 - .005” (.0762mm - .127mm). So, from the example above, a .900” (22.86mm) crease rule would be appropriate for steel base, and a .902” (22.91mm) crease rule for plastic film base matrix. See Diagram 2.
A
+
Diagram 3
Carton appearance considerations
Depending on the flute:
I was once asked to include a company’s design team in one of my creasing presentations; in fact there were more
.937
Diagram 2
Matrix selection formula The formula for selecting the correct matrix size for any corrugated board is: twice the board thickness crushed plus the thickness of the crease rule. This equals the suggested width of the matrix. The minimum depth of the matrix should be equal to the crushed
+ C
designers present than press operators. The biggest question discussed was the issue of cutting from the front or back side of the carton. Ultimately there are advantages and disadvantages to each, but in the end we are trying to satisfy our customer’s demands. The appearance of
• A bead on the inside of a carton presents a smooth, slightly rounded outside corner of a finished carton. (Cut from face side.) This will depend on the presence, and the caliper and quality of a printed label or liner. • In many cases, a bead crease formed on the outside will be visible. An outside bead crease may have a shadow, or an indentation may be visible which is caused by the matrix or counter if the specified depth is too great. (Cut from the back side.) • Many times we have to cut from the back side because the bulk of the material creates pressure on the outer liner, causing it to crack. However we do have some control over this by changing the counter or crease rule specifications.
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14 | The Corrugator | January – March 2013
This “D” profile shaped rubber is common on solid board die cutting to clamp the sheet firmly in place to prevent breakage of nicks. The same effect can help reduce flaking of label stock when cut from the back.
Creasing difficulties
Diagram 4 • E & F flutes are easier to convert cutting from the face with the bead on the inside simply because there is less material. • B and C flute can be cut from the face side, but specifications may be affected when folding, especially in the direction of the flutes. Remember, corrugated will fold at the weakest point. So, if you refer to Kevin’s diagram again, a carton could possibly fold on the same hinge point on all four corners and the glue flap may come up short or long. • Smaller bead creases will have less affect on those carton specifications. • Sheet curl after label lamination may force a job to be cut from the back. Consider label or liner grain direction in board specifications. • If cut from the backside with a label, measures may need to be taken to combat flaking. Below, we take a closer look at this.
Cutting Cutting through corrugated, no matter the thickness, is different than cutting through a solid board. Corrugated will not begin to cut until the material is crushed and if a label has been applied and the label side is down, the label is the last thing being cut through. If we are accomplishing true kiss cut diecutting, the knife is not going to penetrate 100% of the label. It is ideally going to cut through 80%-90% of the material while the remaining percentage will burst. Paperboard diecutters who are accomplishing kiss cutting rely on this to prevent knife damage. Because of the different make up of label stock, the grain direction, the corrugated liner, and the fact that we strive for kiss cutting, the result is often flaking along a cut edge. A firm rubber on the knife is important to combat this flaking. Many times a firmer profile rubber will help this situation. See Diagram 4.
Creasing or scoring across the flutes is generally not a problem in corrugated as there is not the variation in material as there is with creasing in line with the flutes. However, creasing across the flutes is not immune to wavy appearance. When the flutes are in line with the direction of the crease, the peaks and valleys of the fluted material tend to take their own direction when compressed or forced into a matrix or counter channel. Remember, the stock will fold at the weakest point. See Diagram 5.
Normal Bead
Reduced Bead Diagram 6
Diagram 5
Diagram 7
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16 | The Corrugator | January – March 2013
Cracked scores
Box scores, rollovers
Cracked scores in paperboard are often overcome by reducing the size of the bead which relieves the stress on the outer layer of paperboard. When folded through 90° or 180°, this outer layer (the spine Diagram 1) has less material to stretch around, making that spine less likely to crack. This is accomplished by either increasing the rule width or reducing the channel width. Again Kevin Carey has referred to this as “reduced bead creasing.” In some cases, this works with corrugated as well. See Diagram 6.
Multi-crease and off-center matrix are good solutions for close scoring in folding carton diecutting. Flat bed corrugated close scoring, especially B and C flute, presents a whole new set of challenges. For example, if one looks at box scores, or rollovers, which is the most common close score requirements in corrugated, a multicrease, or off-center matrix often interferes with the sheer bulkiness of the corrugated. This causes excessive draw on the material and bunches up the stock in the center of the roll over causing either fracture problems or uneven and unsightly creases.
Reduced bead formation in corrugated helps narrow the fold point and relieve stress in the flute direction, but generally will have no affect across the flutes. When cutting from the face side, test results have shown that it is generally best to use a .2mm (.007”) narrower matrix in the flute direction as opposed to across the flutes. When cutting from the face side, a narrower bead is generally better. Cutting from the back side, in many cases a wider bead will help relieve cracked scores since we are essentially making room in the channel for the fluted material to do what it will. However, the trade-off is lesser defined creases.
In order to avoid these problems, it has been proven that a good result can be obtained by eliminating this center formation in multi-crease and off-center matrices. Film base multicrease matrix is constructed in such a manner that this center strip of material can, with enough force, be pulled away from the film base, thus eliminating this interference. But, there is a matrix manufactured with a modified locator and a wide channel to accept multiple crease rules. This type of matrix is an excellent, easy-to-use alternative for forming box scores in flat bed corrugated applications. See Diagram 7.
U Bend matrix for Box Scores
Formula to calculate matrix size = .030 E flute crushed .030 X 2 = .060 + rollover width .250 .310 .310 .0394
= 7.86mm
1.0 X 8.0mm U Bend
Conclusion The demands of packaging solutions to advertise and attract consumers as well as rigidly protect the products they contain seems only to escalate from year to year. We as producers of package and display goods need to continually rethink our methods and strive to meet those demands. I hope that what I have shared with you helps your company focus on the solutions.
This article is reprinted with permission from the The Cutting Edge - the magazine of International Association of Diecutting and Diemaking (IADD) 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.
Diagram 7
www.iadd.org for more information.
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Recognising when to replace cutting dies Shutting down a multimillion euro press or delivering orders late because of cutting die failure can often be prevented. The key is recognising the sings before the entire die needs replaced.
I have been in the corrugated converting industry for well over 30 years and still have yet to find the magic button to push, telling a press operator when the cutting die he is running has seen better days. I we have used labels to track the number of impressions and even installed rotation counters like an odometer in an attempt to get the most mileage from our tooling. While these methods are helpful, neither is foolproof to guarantee here is “one more run” left in the tank for that cutting die;
ultimate customer; whereas new cutting die costs often can be recovered. For that exact reason, converters understandably press their luck and hold their breath for the one more run.
The risk of stretching your luck ne too many times can result in a customer reject or significant downtime on press. On the other end, replacing tooling is typically a pIant expense that is not passed on to the
Fortunately, the units can be brushed, most of the hair removed and the boxes can often be salvaged. The cuffing die rule is replaced and you’re back in Business. Increasing impression slightly in an effort
Flatbed cutting dies which cut onto steel plates give us warning signs that things are going south in the way of angel hair clinging to the units. This s caused from the steel cutting rule losing its sharp edge and becoming dull and flat.
Rick Putch Managing Director, Dicar to improve cutting will result in a very loud and ugly “crunching sound” of the steel rule slamming onto the steel cutting plate. Soft anvil rotary dies are not quite so easy to recognise the signs of wear, however it is possible if you look closely. The main reason rotary dies are often used beyond their effective performance condition is they cut into a soft urethane surface. Adding slightly more impression into
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22 | The Corrugator | January – March 2013
Left: Flatbed cutting dies which cut onto steel plates give us warning sings that things are going south in the way of “angel hair� clinging to the units. Below: Many times the condition of a cutting die deteriorates to the point of being obvious.
urethane does not give the same loud warning signs of dies that cut onto steel plates, but doing so results in damage to the dies, boxes and even the machine. The four basic components of a conventional rotary soft anvil cutting die are the plywood shell, steel rule for cutting creasing and perforations, ejection material, and miscellaneous pre-fabricated items such as seamless punches and PertA-Type letters. These parts do not wear at an even pace, therefore unless there is major failure of a component, the press can continue to rotate and produce inferior product or possibly rejected product. Cutting dies are in their best condition when they are initially delivered. Many times the condition deteriorates to the point of being obvious, however that transformation did not happen overnight. The key is recognizing the signs early enough before the entire die needs replace.
l
Shimming of the lead edge is a clear indicator failure is Imminent. If the plywood delaminates, then it is not uniform enough to support the ejection material. Shimming of the lead edge is a clear indicator failure is imminent. Removal of one piece slots prior to cutting them at the radius often causes delamination of the plywood.
Steel Rule: Cutting, creasing and perforating rules stamp out the shape of the box and strategically place folds or perforation lines to bend and/or detach flaps and panels within the design. If there are gaps in the knife, complete cutting is not possible and scrap will remain in the finished unit. Adding impression is often a perceived solution to complete the cutting and stripping. A small gap of only 1/16 w (1.5mm) on a knife such as a small vent hole cutout is trouble. The section of waste within the cutout is so small and lightweight, it cannot be shaken or fall off with gravity. Do not add impression to resolve this issue... repair or close the gap.
Basic Components Plywood shell: The plywood is the chassis of the box design. If it fails then the steel rules are no longer in the right position or supported enough to remain stable and rigid. To successfully cut or crease the corrugated board, the steel rules must not flex or fold over on impression.
Removal of one piece slots prior to cutting them at the radius often causes delamination of the plywood.
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24 | The Corrugator | January – March 2013
Over compressing certain rubber product destroys the cells within. We often overlook the abrasive properties of the paper being diecut and the wear it places on the cutting rules. We often overlook the abrasive properties of the paper being diecut and the wear it places on the cutting rules. While most recycling facilities can sort metal banding and other metallic items at the pulper, some items other than kraft paper unfortunately make their way into the reclaimed board. In addition, metallic inks and foil laminated combined board can significantly reduce the cutting rule height and alter the tooth geometry.
This is very hard to detect as it happens gradually and the rule still looks “serrated”. Adding impression to compensate results in crushed edges and score cracking. One way to check the wear is to caliper a scrap knife. They are easy to remove and reinstall. l
Ejection Material: This generally comes in the form of rubber blocks or custom cut shapes conforming to the design. Mechanical plastic and
metal ejectors can be used as well. Regarding rubber, it serves as a sheet stabilizer, waste ejector and a transfer device all within a split second. Heat, compression and abrasion are the biggest enemies of rubber products on the cutting dies. Over compressing certain rubber products destroys the cells within the rubber. Perf-A-Type Letters are molded zinc letters and numbers that “pin-prick” the inner liner, allowing identification without printing. These little characters are less than a couple bucks each but if ignored can cost tens of thousands of dollars in rejected, misidentified product.
l Miscellaneous:
Pert - A - Type Letters are molded zinc letters and numbers that “pin-prick” the inner liner, allowing identification without printing.
A small gap of only 1/16 (1.5mm) on a knife such as a small vent hole cutout is trouble.
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26 | The Corrugator | January – March 2013
Walk the floor of your plant, and look around for the signs, such as: 1. Paper trim packed around the knife; 2. Damaged rubber that has been worn down or stacked double up and 3. Cracked rules, particularly on corners and near bridges. Just as your car needs maintenance, so do cutting dies. Shutting down a multimillion Euro press or being late for delivery to a multimillion Euro customer because of a cutting die failure can often be prevented.
Damaged rubber that has been worn down or stacked double up.
Rules, particularly on corners and near bridges.
Paper trim packed around the knife
Rick Putch is Managing Director of Dicar Consulting Services Worldwide headquartered in Pine Brook, N. J. He can be contacted at 412-979-3775 or at rickp@dicarinc.net This article was first published in International Paper Board Industry Nov. 2011, and is reprinted here with the author’s permission.
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Impact of the dimensions on compression strength of a corrugated box. A corrugated box is subject to static loads such as those experienced by it during stacking in warehouse, as well as, dynamic loads such as those experienced during transit when they are stacked in a truck. Stacking strength of corrugated box is a key requirement for the performance of the box during transportation. Stacking Strength is defined as the maximum compressive load that a corrugated box can bear over – • A given length of time • Under given distribution conditions, without failing. Compression Strength is related to Stacking Strength but is actually quite different. Compression Strength is the “Dynamic” load applied on a corrugated box in a compression tester at the rate of 12.7 mm per minute and is extensively used as a purchase acceptance standard. The compression strength is related to stack load that a box experiences during warehouse stacking. It a simple relation:• Compression strength = stack load on box multiplied by the safety factor. The safety factor also called as environmental factor depends on Stacking time in warehouse, humidity, pallet patterns, etc. This factor can range from a low 2.00 to a high 6.00 depending on the environment that the box experiences during storage and transit.
In 1963, R.C. Mckee and his co-workers developed a simplified formula to relate top load compression strength of vertical flute boxes to combined board properties & box dimensions using principles of engineering mechanics. The box compression load ‘BCT’ is given by – BCT = c (4P)(2-2b) (Pm)b (Dx.Dy)(1-b)/2 .Z(2b-1) .k(1-b) • Where – Pm: Edgewise compression strength of the corrugated board – Dx & Dy: Flexural stiffness in Machine Direction & Cross Direction respectively. – Z: Perimeter of box – k: Buckling co-efficient – b: Constant determined to have a value of 0.76 from the analysis of data on compression study. The Buckling co-efficient ‘k’ is related to ratio (d / Z) where – d: Depth or Height of box. – Z: Perimeter (2L + 2W) of box. When a graph of k(1-b) Vs (d / Z) ratio is plotted for b=0.76, the value determined from the analysis of data from box compression study, it was observed that k(1-b) = k0.24 was nearly constant at 1.33 for (d / Z) ratio ≥ 1/7.
Ram Kumar Sunkara S. S. Consultants Further the flexural stiffness test is not an easy test to perform. R.C McKee and his team looked at replacing the flexural stiffness by some other easily measurable parameter and found that it can be replaced by board caliper. Substituting board caliper for flexural stiffness in the formula resulted in a simpler formula with very little loss of precision. Analysis of the data from the box compression study showed that there is correlation between composite flexural stiffness (Dx . Dy)1/2 and edgewise compression strength times caliper squared. With this substitution the formula simplified. The equation BCT = 5.874 Pm . T0.508 . Z0.492 fitted the data on box compression study. ‘T’ being the caliper of the board.
In 1943, Little developed the first explicit analysis of box compression strength in terms of short column strength, flexural stiffness in Cross Direction and length of square box. In 1950, comprehensive standards for compression test were published by Grunday and Balkema. Contd. on page 32 The Corrugator | January – March 2013 | 29
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Contd. from page 29 R.C. McKee further simplified the formula to BCT = 0.599 x ECT x Sq. root ( Z x T). ECT is edge wise compressive test of board in kN/m, Z is perimeter of box in mm, and T is board caliper or thickness in mm. The above simplified formula has been used by us for a long time and found it to be a very good work man formula. We have observed certain limitations while using this formula. It was independent of the box height. Although the length and width of box has come into picture in form of perimeter, it lacks the impact of the ratio of length to width. It is known that the 2:1 ratio of length to width gives use optimum board area and therefore we investigated for the impact of changing box dimension from 1:1 to 2:1 on the compression strength. We found that there was a drop on an average 4% in the compression strength when length to width ratio was changed from 1.00 to 1.50. These observations lead us to investigate the impact of length to width ratio on compression strength of the box. Due to introduction of foot print concept in box dimensioning to fit the standard pallet sizes, we are now producing boxes with different heights but having same length and width. When we tested the boxes of same foot print but having different heights, we found that there was impact of height on the compression strength. We observed a variation up to 18% in compression strength due to changing heights. The compression strength of box is estimated using the formula: BCT = BCTM X CFLW X CFD
where,
BCTM is box compression as calculated using McKee’s formula, CFLW is the correction factor for length to width ratio, CFD is the correction factor for the depth. We present below our observations of impact of length to width ratio and depth of the corrugated box on its compression strength.
32 | The Corrugator | January – March 2013
Length to Width Ratio Keeping the height of the box at 250 mm, the length to width ratio was changed from 1.00 to 2.50. The compression correction factor for the L/W ratio 1.50 was taken as 1.000. When the L/W was decreased to 1.00 the correction factor increased to 1.040 and when the ration was increased to 2.50, the correction factor reduced to 0.886. See the table 1 below for the correction factor. Table 1: Correction factor for length to width ratio L/W Ratio 1.00 1.10 1.20 1.30 1.40 1.50
Factor 1.040 1.032 1.024 1.016 1.008 1.000
L/W Ratio 1.60 1.70 1.80 1.90 2.00
Factor 0.990 0.977 0.966 0.955 0.943
Figure 1: Graph of L/W ratio Vs correction factor
L/W Ratio 2.10 2.20 2.30 2.40 2.50
Factor 0.932 0.920 0.910 0.897 0.886
The co-relation between the correction factor and L/W ratio can be expressed in formula as follows: CFLW = 1.103 – 0.045 x (LWR) – 0.017 x (LWR)2 , Where LWR is the length to width ratio and CFLW is the correction factor. Depth factor For the same foot print, the height was increased from 100 mm to 750 mm in multiples of 50 mm and compression strength was measured. The correction factor was taken as 1.00 for box height of 250 mm. As the box height was decreased the correction factor increased to 1.18 and as the height was increased from 250 mm the correction factor decreased to 0.82. See the table 2 below for the correction factor. Table 2: Correction factor for the depth or height of the box. Depth or height 100 150 200 250 300
Factor 1.180 1.090 1.040 1.000 0.970
Depth or height 350 400 450 500 550
Factor 0.940 0.920 0.900 0.880 0.865
Depth or height 600 650 700 750
Factor 0.850 0.840 0.830 0.820
Figure 2: Graph of Height of carton Vs the correction factor.
The co-relation between the correction factor and depth or height of box can be expressed in formula as follows: CFD = 2.7 X (Depth)-0.18 Using the above correction factors, we have been able to calculate more accurately the compression strength of the cartons.
Mr. Ram Kumar Sunkara, is a prominent Consultant and Advisor to Paper based packaging Industry. After completing his Masters from the Mumbai University, he went on to pursue Certificate in Kraft Pulping, Paper Machine Operation’s, Waste Paper Recycling, and Paper Machine Auditing from USA and Canada. He has more than 25 years work experience in manufacturing of specialty paper, Corrugated boxes, paper cores and tubes, fiber drums, and multi-wall paper bags. Being an active member of the Governing Body of Indian Institute of Packaging & the Research Advisory Board of WICMA - R & D center, many of his Papers & Articles have been published. He is currently Co - Chairman of the R & D Centre of the Federation of Corrugated Box Manufacturers of India. He is currently the Chief Technical Advisor of S. S. Consultants, Packaging solution providers
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Our Experience with Semi Auto Stitcher
We have a Chinese Board Plant and a Chinese Printer. All the while we have been focusing on the productivity of the board plant and the printer – to maximize the production of both these departments. As far as the stitching department was concerned, we never really gave it a thought, and just kept adding the number on manual stitching machine that we bought for a few thousand rupees. But then, we came to a situation where we realized that this is not he correct thing to do. We were getting really stuck because of this. It became a real bottleneck. As we all know that our manual stitchers are highly dependent on very skilled labour. As the production increases, requirement of skilled labour, skilled stitchers, keep increasing. And at my factory I know that stitcher is the highest paid guy. If he get 200 or 100 rupees more, he will go to the neighbouring factory. And if you have to call him back you need to shell out those Rs. 200/- our production is totally dependent on the stitchers.
PROBLEMS WITH MANUAL STITCHERS l Highly depended on skilled labour and large workforce required. l Productivity can not match the output of printer slotters. l Large number of machines required and hence space. l Material handling problems and high labour requirement.
Since the machine cannot match the productivity of the printer, if you have multiple machines more labour is required which is a bigger headache. Space requirement also increases for number of machines and their material handling problems like feeding the machines, you have to pick up the material from the machines, take it to the packing section, or inspection, whatever, So basically manual stitchers are not going to help us to achieve our production targets. We decided to go for semi automatic stitcher even though on paper we were not convinced that payback period or returns on investment are satisfactory. We still felt that we should go for a semiautomatic stitcher. So we went for a single head stitcher that means single piece box or a single flap box.
36 | The Corrugator | January – March 2013
Sanjay Rajgarhia Perfectpac Ltd. The machine specifications are like this: GENERAL SPECIFICATIONS l Machine type : Single head (1pc) stitcher l Stitching speed : 400 stitches / min l Stitches number : 3-99 l Stitches pitch : 35mm - 60mm l Stitches type : Single, Double, Tie Stitch
When machine was installed we were very excited, very happy. But later we started receiving the problems. The supervisors and workers started thinking that their importance will go down.
Benefits of Semi auto stitcher
INITIAL PROBLEMS l
Resistance on paper of workers and supervisors.
l
lack of sensitivity to machine maintenance requirements.
l
Machine out put affected if quality of creasing of Board is not good.
l
Machine output affected if variation in wire quality.
So they were saying board is not square, the flap is not meeting the machine is not staring the wire is short etc. also manual stitcher we were using did not require any maintenance, but this machine being more sophisticated required cleaning, oiling, greasing, taking care of the electronics etc. also if the creasing of the board is not good, you will not be able to get good productivity. Because the worker will spend more time in aligning, in squaring the box and also if the stitching wire is not proper, if there is a variation in the caliper or gauge, or if the quality of the wire is not good, it affects the productivity of the machine. We got over our initial problems. After a few months we felt that everything was on line we were able to actually enjoy the benefit of the semiautomatic stitcher.
l
Productivity 2.5 - 3 times that of manual stitcher and hence lower labour requirement.
l
Semi Skilled labour required.
l
Accuracy in pin spacing.
l
Space saving due to lower number of machines required.
l
Better material movement and work flow.
l
Inspection and packing stations are reduced.
l
Minimal spares and maintenance cost.
l
Suitable for semi auto plants also.
Conclusion The cost benefit ratio or pay back period of Semi Auto stitchers may not justify investment in them. However, they should be considered an essential part of the equipment for converting plants for enhancing productivity, smooth work flow at the shop floor and reducing labour dependency
Sanjay Rajgarhia is a well known corrugated box manufacturer from Delhi. He is the ECO of Perfect pack ltd.an active member of NICMA and is on the managing committee of NICMA & FCBM. This is a presentation made by Sanjay Rajgarhia at one of the Technical Session during 40th FCBM Conference hosted by Nicma
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Waste Control in Corrugated Box Plants
K. R. Ramaprasad The South India Paper Mills, Printing & Packaging Division
Besides the standard allowances we don’t get paid for the paper wastage lot of MNCS do not allow.
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40 | The Corrugator | January – March 2013
Head Office/Factory 770, Dang Ha-Dong, Seo-Ku, Incheon, Korea Tel.:+82 32 564 5013/4 Fax.: +82 32 565 5755 Website: www.insunco.com E-mail: insun@insunco.com
INSUN CO. Korea
Manufactured by
Counter Ejector
Strapping Wire Holder
India Office Address: PLOT NO. 26, METHA NAGAR, M.M.C. POST, CHENNAI - 600 051. Mobile: 095662 39767, 098849 50600
Stitcher
2,800 x 12,000 mm
M/C Dimension
Sheet Thickness
Main Power
Max. Stitching Speed
15 Kw
85 Sheets/Min
180 M/Min
3,100 x 13,000 mm
300 x 900 mm
ES-32
3,500 x 13,000 mm
300 x 900 mm
1,200 x 2,900 mm
Corrugated Board 3 – 10 mm
300 x 900 mm Max. Belt Speed
1,000 x 2,200 mm Min. Sheet Size
ES-28 1,200 x 2,500 mm
Specifications ES - 25 Max. Sheet Size
Model No.
AUTO FOLDER GLUER + DOUBLE STITCHER + COUNTER EJECTOR + BUNDLER
Contd. on page 45 The Corrugator | January – March 2013 | 41
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44 | The Corrugator | January – March 2013
Contd. from page 41
It is not that one person can handle that. In the paper mills also, if they have not selected the right truck, If they are not properly loaded, the rolls get damaged. Vertical loading with the clamps is preferable.
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46 | The Corrugator | January – March 2013
You can see the body of the truck with all the mails and damaged floor. Because of this kind of transportation the stock is going to be damaged.
In many plants, it so happens that the unloading is done on a tier. The roll jumps from the tier and gets unloaded on to the floor. This results in a damage to the paper roll.
Because of the above reasons a lot of waste can result Proper care has to taken to avoid such waste.
I conclude with these meaningful words by Robert F. Kennedy.
“The future is not completely beyond our control. It is the work of our own hands.” - Robert F. Kennedy.
Damage can happen due to wet conditions. If they are pushing around rolls on a dirty and damaged flooring of the storing area, lot of damage can happen.
This is presentation done by K. R. Ramprasad - Printing & Packaging Division of South India Paper Mills at one of the Technical sessions organised during 40th FCBM Conference held at Delhi, hosted by NICMA.
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Corrugated Industry on the move The corrugated packaging industry isn’t standing still. The industry is constantly exploring new ways to improve the effectiveness and efficiency of its traditional packaging solutions, by looking at new grades of paper and surface treatments. At the same time it is looking to corrugated engineering - as ingenious as origami -to extend its range. Corrugated packaging has always offered protection without loss of flexibility, and the industry has responded to the needs of new, more efficient distribution systems. In the future, the innovative use of materials and combinations of components will ensure that corrugated packaging remains the most economic and hygienic packaging solution. At the cutting edge of R&D, the industry is already exploring ways to make this vision a reality by effectively integrating smart chips into corrugated packaging. The goal is to create packages that are so easily identifiable and secure, they will make barcodes look primitive. Technical advances during the last decade have produced weight savings of 20 per cent without impairing protective or structural qualities. And the drive for improved weight reductions continues. Advances in material science are leading to new types of structural products such as corrugated pallets that offer huge economic and other advantages. Corrugated board has already evolved to answer more user needs than any other type of packaging. This preoccupation with innovation extends to improving the ways in which the industry relates to customers – to provide new commercial opportunities. With so much thought going into corrugated packaging, there are some great benefits in store.
No other material has been used so creatively. Industry R & D has provided a stream of ever more diverse single-piece, interlocking packaging. The origami of corrugated packaging releases infinite design possibilities and exploits the load-bearing properties of easy to erect, engineered structures. Advance high-quality printing makes short print-runs economical, and allows more information to be incorporated into bas codes. Material science is also creating new grades of paper and surface treatments.
Closer-Fitting Packaging By eliminating any room for movement, precision, die-cut packaging provides highly reliable protection during transit. It is designed using advance CAD/CAM methods. Single piece packages provide fast machine packing, eliminate separate components and secondary materials. Advanced plant achieves high production runs, consistently reproducing the tightest engineering tolerances. Apart from reducing damage, it also leads to packaging that is much easier to handle at the point of sale.
Micro flutes bring macro benefits The newer micro flutes are replacing carton board in a variety of applications. Since corrugated is stronger, packs are strong enough to go onto pallets and then straight onto shelves from where they can be conveniently carried home by customers who take the packaging with them.
Higher strength, lighter weight packaging Tulip International produces thin cuts of vacuum-packed meat. Its new and acclaimed duo packaging uses less material to achieve higher levels of protection and is a triumph f inter-industry co-operation across Europe. The design uses a special corner post feature to achieve higher strength using less material than similar pack styles and enables the manufacturer to reduce the primary pack specification. The Duo pack gives retailers more efficient supply-chain management and in-store merchandising and meets manufacturers’ needs for efficient packaging lines, product protection and brand reinforcement.
Packaging for Fragile Planet The corrugated industry is proud of its record for recycling - over 70% of the fibreboard produced each year is made from recycled fibres. Collection of corrugated packaging for recycling Corrugated board is not made from tropical forest hardwoods - they are
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entirely unsuitable for the process. In fact the industry uses fast- growing softwoods, which are being replanted faster than they are being used. Corrugated packaging is a reusable material made from a renewable resource. As the world’s population expands, so does the demand for packaging but due to innovation and efficiency in packaging, it is increasing at a slower rate than the population. The urgent need is for packaging that has the least harmful impact on the planet. Of course, it will also have to be economic to use. Corrugated packaging provides the balanced solution. The industry has always invested large sums in recovery and recycling processes. It is now so effective that, in the UK alone, 84916 of the 2 million tonnes of fibreboard produced each year is recycled into new packaging. A far higher percentage than any other packaging material. The industry already exceeds recycling targets for years to come. But what makes corrugated packaging superior any other material is its recyclable nature? Surveys reveal that it is favoured about anything else by environmentalists and consumers. Corrugated packaging is made exclusively from sustainable forestry resources. The 30 percent of paper that is made from woof sources such as thinnings (the natural waste product of good forest husbandry) only comes from farmed forests and paper manufactures are replanting trees faster than they are being consumed. Typically, fast growing softwoods such as pine and
spruce are used. Tropical forest hardwoods are unsuitable for packaging papers. Huge investment in advanced technology means the processes for manufacturing corrugated board are increasing energy efficient and satisfy the most stringent equirements of environmental legislation. And the industry continues to search for even lower emissions and energy efficiency. The corrugated packaging industry is proving that environmental concerns and economic packaging are not incompatible. Bigger savings are not made at a cost to the planet. This is because corrugated packaging does not destroy forests, does not use tropical forest hardwoods and does not pollute the atmosphere. Achieving environmental compliance can produce a healthy profit. Apart from ensuring the long term availability of raw material, recent advances have reduced manufacturing costs, packing and distribution costs and led to easier recycling and waste disposal processes. The industry continues to look at packaging that has a lower environmental impact through the development of single piece, lower weight case.
Measuring the Environmental. Impact of Paper Corrugated packaging is made from paper, the only packaging material manufactured from a renewable source. The paper cycle will continue in perpetuity
provided the harvest of timber does not exceed forest growth and that new trees are planted.
Protecting the forestry resource Scandinavia is one of the major sources of wood pulp for paper. In Sweden forest growth or replanting exceeds annual felling by up to 35%. One of Europe’s leading manufacturers of corrugated packaging owns large expanses of forestland there. Its ecological policies demonstrate how the industry takes responsibility for ensuring the perpetuity of its raw materials. One of the main priorities is to preserve the bio diversity in the forests through ecological landscape planning and logging practices Seed trees are left on around 45% of the forestland with 12% in combination with planting. These practices and their effects are regularly monitored through ecological audits.
Using less material in every package Producing stronger, lighter material is not only an engineering and cost issue, it is an environmental one too. Major producers of corrugated packaging across Europe now use the latest CAD/CAM technology to produce better-engineered solutions and the star is the single-piece, mono-material, die cut, machine- erectable package.
Source: www.paper.org.UK information / corrugated / move.html
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FCBM News Looking back at the 41st FCBM Conference Mr. Naresh Khanna, Editor of Packaging South Asia had attended the 41st FCBM Conference in Mumbai. The December 2012 Issue of Packaging South Asia featured Mr. Harish Mehta on the cover page. The Editorial titled “The Future is Corrugated” highlights the versatility of corrugated. Reproduced here is the Editorial:
The future is corrugated Sculpture and architecture in packaging Nowadays just as graphic designers speak less and less about typography, packaging designers rarely speak about structural issues. The design talk normally ranges from ‘the first moment of truth’ to issues of brand integrity and brand protection. It was thus doubly refreshing to attend the FCBMI conference in Mumbai — firstly because the modest kraft corrugated material of our country was being discussed in the context of a huge upgrade. There was talk of improvement, standardization and expansion by the kraft paper mills. There was talk of the improved machines for corrugation and in one futuristic presentation, of an all-in-one corrugation and box making and digital printing machine that resembled a Boeing dreamliner. There was talk of improved flexo printing in four colour on bleached white kraft liner for which a number of machines from Emba and one from Bobst have been ordered. And finally there was talk of the humble corrugated kraft, heretofore used mainly for big boxes ‘shippers’ being used creatively as an environmentally and cost friendly material for interior decoration, luggage, for portable toilets and for amazing POP displays and innovative packaging. Two packaging designers spoke at the conference — Vinay Mehta of VENTiT and Haresh Mehta of Jayna Packaging. While Vinay spoke of his patented innovation for the delivery of hot pizza, parathas and any other food that needs to be delivered healthily and cheaply, Haresh Mehta spoke of innovations in interior design of shops and furniture and POPs. Both designers are emotional about the structure of corrugation. While Vinay Mehta speaks of corrugation as a wave form and a thermal insulator and a steam extractor, Haresh Mehta speaks of corrugated as a classical architect — he speaks of its structure as columns and arches. Perhaps to illustrate his ideas about the strengths of this material and form of packaging, Haresh Mehta creates sculptural forms. Since he understands the inherent strength of good corrugated material, he wants to differentiate his ideas and production capacity from the more modest quality of corrugation that is prevalent in our country. And thus he creates large structural forms such as tables, chairs, beds, luggage and even the interior of an entire shop in a mall. For him the power of corrugation comes from both the fluting and from the possibility of multiple layers. Naresh Khanna, editor@ippgroup.in
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‘Reprinted with permission from Packaging South Asia, December 2012” www.packagingsouthasia.com.
a substitute of Electricity Board’s supply for domestic uses other than running of machinery and equipments.
Annual General Meeting and Technical Seminar on ‘Solar Energy’ The Annual General Body meeting of Kerala Corrugated Box Manufacturers Association was held on 23-2-2013. Along with the AGM a Technical Seminar on ‘Solar Energy and Corrugated Industry’ was also organised. Shri R.R. Ankola, President FCBM inaugurated the seminar. Mr. N.X. George, Chairman, Technical Committee, welcomed the delegates. Mr. Georgekutty of ‘Lifeway Solar Devices’ and Mr. Sankar of ‘Team Sustain’ presented papers. They explained the process of setting the solar panels, functions and storage of energy received through solar panels. Mr. Ajay Gupta of Asian Pulp and Papers, Bangalore also presented a paper on ‘Quality parameters of imported Kraft paper’.
Mr. R. R. Ankola appreciated the President and members of the Kerala CBMA for organizing a seminar on such an innovative subject. He also urged to increase the membership of the Association by way of inducting at least one new member by each member. He also appreciated the activities of the Association. The Technical Seminar was attended by about 75 corrugators from different districts of Kerala. All the participants appreciated the idea of selecting such a subject especially when the State is facing acute shortage of power and high cost of energy charges.
The main aim for selecting the subject of ‘Solar Energy’ was to find out whether this energy could be utilized profitably as The Annual General meeting opened with the welcome address of Mr. Xavier Jose, President of KECBMA who briefly spoke on the activities and achievements of the Association. He also stated that a team of about 20 corrugators are visiting Sino Corrugated Exhibition being held in China in April, 2013. The Secretary, Mr. K.J. Pratish presented the Annual Report of the Association and Treasurer, Mr. Bijoy Cyriac presented Audited Accounts of 2012 and the same were adopted. The meeting was followed by a family gettogether, cultural programme, interaction, fellowship and dinner.
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Seminar on Opportunities for Improvement in Semi Auto Plants The Marathwada Division of WICMA had orgnised A Seminar on 1st March 2013 Dr. Ulhas N. Gaoli inaugurated the seminar FCBM President Mr. R. R. Ankola was felicitated on the occasion. Papers were presented on the following subjects: • Future of Semi Auto Plants in India • Selection Of Kraft Paper For Optimum Performance • Low Cost Automation & Quality Improvements • Defects In Paper -Impact On Costing • Changing Role Of Conventional Corrugation Plants In Today’s Scenario • 2013 Budget - How Will It Affect Corrugated Industry • An Open House Session was held at the end. This was followed by Cocktails & Dinner.
Mr. Raju Ankola, President, FCBM was the Chief Guest at the Seminar held by GCBMA at Ahmedabad on 24.03.13.
WICMA R & D Centre has announced Certificate Course in Corrugated Packaging (Automatic Process). The Course will be held in Mumbai at Hotel Kohinoor Continental from 22nd April to 26th April 2013 Details from Mr. Y. M. Rao, | wicma@wicma.com or Ph. +91 22 2850 6716
60 | The Corrugator | January – March 2013
Details will be featured in the next issue.
2nd Managing Committee Meeting of FCBM was held at Hotel Jaypee Siddarth, New Delhi on 19th March 2013
The 2nd Managing Committee Meeting of FCBM was held at Hotel Jaypee Siddarth, New Delhi Implications of Union budget was presented by Mr. Bharat Kedia through an interactive DVD. President released interactive CD with complete details on Excise for the benefit of FCBM Members. Besides, other matters were discussed. On the earlier day, i.e. 18th March, Mr. Subhash Goel, President, NICMA and members of managing committee of NICMA hosted a Welcome Dinner & Cocktails Excellent fraternity and fellowship was witnessed on the two days.
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Trial Packaging of Tomatoes Conducted at Haldibari in Corrugated Boxes Further to commitment made in a seminar held at Haldibari on 27.07.12 to convince the traders & farmers about the practical viability of packaging of Tomatoes in Corrugated Boxes. EICMA conducted a packing trial of tomatoes in Corrugated Boxes on 23.02.13 at Haldibari. The programmes have been initiated by Mr. Milan Kumar Dey, Chairman; New Market Development Committee, FCBM with active support & inputs from the Managing Committee Members.
The space occupied by over 500 empty cartons in comparisn to just over 50 empty wooden / plastic crates Thanks to the efforts of Mr. Anil Kumar Agarwal & Mr. Suroji Pal, members from Siliguri, other traders joined and a hour long formal session was conducted there by Mr. Hemant Saraogi, Past President, EICMA.
further transshipped to Lucknow from there. Over 800 kms were covered and the results were inspiring. In the words of Truck driver “ Jaisa load kiya tha, waisa hi hai”. There was no visible damage and the endeavor was fruitful.
The Traders were explained the benefits of packing in corrugated Boxes by the senior members of EICMA.
Analysis: The packaging of Tomatoes in Corrugated Boxes is inevitable and it is just a matter of time depending upon the demand-supply forces that sooner or later, a new market for 6000 M. T. boxes opens up in the Eastern Region every year, during the Tomato season from January to April.
Team EICMA also applauded Mr. Narendra Kr. Jhunjhunwalas efforts in designing & developing the boxes achieving over 450 kg CS after repeated R & D tests and production trials.
Mr. Milan Dey along with Mr. Hemant Saraogi & Mr. Bharath Kedia demonstrating to traders, the correct way of packing, loading & stacking the cartons.
Post Results : The first lot of Packed Tomatoes were sent to Basti ( U.P.) and
This may well be the first step for packing other fruits & vegetables in other regions of the country.
The trial packaging was conducted in the presence of Government Department officials & IIP representative. The packing, stacking & loading was supervised by over 25 EICMA Members from Kolkata & Siliguri. The truck loaded with Tomatoes in boxes was flagged off by Mr. Biplab Kumar Datta, Past President, EICMA. The Traders were thrilled by the aesthetics, strength, space utility and loadability of the cartons. The labourers were also more than happy while packing in this convenient mode. The trial was thus a huge success.
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Tomato Cartons – Perfect Loadability In Truck
Using Color as a measure of “Quality” Using Color as a measure of “Quality” and “Product Identification” is an important tool that needs to be developed in all Box Plants. During the last year we have offered many discussions and opinions on all the components that control and directly affect the many types of box and sheet plants in our industry. I discussed the various calibration methods that we require in order to properly manage and maximize the mechanical side of our Die Cutters and Flexo Folder Gluers. We offered suggestions that would improve the performance of our tooling suppliers that manufacture Cutting Dies, Printing Plates and of course our Flexo Inks. All of these areas of expertise are necessary ingredients that certainly contribute to the financial success in our plants. I would like to take this opportunity to review one part of our process that is often a challenge to manage and that is the subject of “Flexo Inks”. For all of us, this is certainly an area of opportunity and one that needs some real discussions. There are a number of components that directly affect and control how we print color other than the Ink itself. We will first spent some time on the subject of Flexo Inks and then we will discuss the components that affect how we deliver ink to the sheet. We need to first review and understand the components of ink and their mechanical relationships in a chemical/water based environment. Generally speaking, there are four main ingredients in Flexo inks: Pigment—Resins—Amines—Water. [I will say that there are many different types of Pigments as well as many different types of resins available. I just want to speak in general terms in order to keep things simple for this discussion] As we know the Pigment is the color. It is the
most expensive ingredient in the process. The resins are the carriers in the ink and they are initially responsible for transporting the pigment from the ink bucket through the ink pump, to the chamber head (or nip rolls) onto the printing plates and finally to the corrugated sheet. The Amines offer an alkaline environment in the ink in order for the two components (Pigment and Resins) to have a relationship. The fourth ingredient of course is water. By he way, we call our ink “Flexographic” ink because it is a water-based product. We need to first define what we mean when we discuss pH qualities of ink and how it affects the process. “pH” refers to the Hydrogen Properties of the solution. It defines any solution as an Acid Base, Neutral Solution or an Alkaline Solution. You can see by the description that the inks that we use in our industry are certainly on the alkaline side. (See Slide #1)All over the world the Flexo inks that we use have a pH range from 8.5 pH to 9.5 pH. By the way, these numbers are logarithmic by description. This means that 8.6 is ten times more alkaline than 8.5. 8.7 is twenty times more alkaline that 8.5. So, 9.5 is actually one hundred times more alkaline
Dick Target “On Target Consultants” than 8.5. This is important to understand as this tells us that the pH qualities of our inks are very easy to manage once we understand the basic principles of pH and how it is defined. A pH of 9.5 is not just one point higher than a pH of 8.5. It is one hundred times more alkaline than 8.5. The differential is very large and properly done is easy to manage in the process.
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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
66 | The Corrugator | January – March 2013
Contd. from page 63 Amines. (They are generally called mono-ethanol amines [MEA’S} or in some cases [D-MEA’S] or diluted MEA’S. This is dependent upon the specific formula for the ink and its color. Blues and greens are specific colors and they do require special attention. FLEXO INKS ARE LOGARITHMIC BY DESCRIPTION, WHICH MEANS THAT 8.6 IS 10 TIMES MORE ALKALINE THAN 8.5 AND 8.7 IS 20 TIMES MORE ALKALINE THAN 8.5. Now, all the pigment particles and resins that we use in our ink formulas are “inert” materials. They actually have no activity and are on the same par with sand or dirt. In order for them to have a proper relationship and maybe be chemically active, they need to reside in an alkaline environment. That is the reason for the third ingredient:
There are also several different types of amines that we use in the ink industry and they all relate to the speed at which the amines evaporate. Simply said there are slow, medium and fast evaporating amines and this determines the drying rate of the ink on the sheet.
It is very important to manage the condition of the amines depending what time of year and where you are in the country. In cooler climates (winter time) the inks tend to be more stable. In the summer months, the amines evaporated much faster and the ink looses its color and the viscosity numbers tend to rise quickly. You should have this discussion with your ink suppliers so that they can properly and accurately support you throughout the year. In the ABC slide (See Slide #2.) you can see the Large Circles (Pigment) and the Small Circles (Resins) that encapsulate the pigment particles. The job of the resins (small circles) is to support the pigment particles and keep them in solution until they arrive on the corrugated sheet.
I would also like to point out that the Amines are a temperature sensitive product. When we walk pass the print stations, we frequently smell the inks. Actually, we smell the amines that are evaporating from the buckets. (Remember the Pigments and Resins are inert and they have no chemical activity themselves).
In cooler climates inks tend to be more stable. In the summer months, the amines evaporate much faster, the ink Loses its color and the viscosity numbers tend to rise quickly.
The slide on the left shows ink in its proper “Pigment/ Resins Relationship” and the color is a 74 or 75 Red. You can see that the pH of this red ink is between 8.5 and 9.5 or just 9.0 as a reference. This is controlled by the presence of the MEA’S. I call this “Proper Ink” with its proper Pigment/Resin relationship. If this product is delivered to the sheet the color will be correct. The center view shows ink where some of the amines have evaporated and you can see that the Pigment/Resin relationship has changed and the pigment particles (more dense) are separating from the resins and falling to the bottom of the cell. At the same time, the color is now bleeding into the water loosing its integrity and now coloring some of the resin particles. The net difference is that the color is now changing, getting lighter and we are loosing the proper color that the customer is expecting. Contd. on page 71 The Corrugator | January – March 2013 | 67
Put the Seal of Quality on Your Packaging
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68 | The Corrugator | January – March 2013
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
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The Corrugator | January – March 2013 | 69
70 | The Corrugator | January – March 2013
Contd. from page 67 pH adjuster once an hour throughout the day. When the ink is finished and the crew is placing the ink back on the shelf, add another 2 ounces to the kit just to help sustain the proper pigment/resin relationship until the next time. Now, lets discuss the chemistry of the sheet or the paper. This is never discussed in our plants. The chemistry of the paper that we print on clearly controls the printing process. The chemistry of the Kraft paper or the model white or the coated stock is generally on the acid side of the scale. This is important to understand as this explains why we use the ink that we use. Properly controlled pH ink will print consistently on an acid based paper and the printing process will complete itself. Color is certainly a key ingredient in our process and in most cases, properly done, it will encourage our customers to accept the order and not look for any possible defects in the box itself. In our next article, we will discuss how to better manage the handling of our inks and proper maintenance of the cells on the anilox rolls, surface tension on the printing plates and the plumbing system. Stay tuned as this is an important part of the process. Earlier, I said that the job of the resin particles is to transport the pigment and keep it in solution during the process. The resins actually have two jobs in their whole life. The first job is to transport the pigment and their second job is to fix or glue the color to the sheet. As the resins start to separate from the pigment particles, caused by the evaporation of the amines, the resins also start to touch each other. At this point they do become sticky. Properly formatted, when the ink arrives on the sheet, the pH drops, the ink separates, the pigment is absorbed into the paper and the resins fix or glue the color to the sheet. Also at this point, the amines have totally evaporated; the water is absorbed into the sheet as well as the pigment or the color. We call this printing!
During the production day, as the amines have evaporated, the viscosity will change. The Ink will become thicker and the color will not be correct. Over the years we have trained our operators to add water to the ink in order to reduce its viscosity. The ink became thicker (Increased Viscosity) because the amines evaporated, we lost the proper pigment/resin relationship and the resins started touching each other. The pH of water is generally neutral (7pH) and now we are adding a lower pH material (water) to already disturbed ink due to the evaporation of the amines. The proper technique is to replace the ingredient that evaporated from the solution. That is amines or a proper pH adjuster. Your ink company should supply this adjuster. I would suggest that the crews add 2 ounces of a proper
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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72 | The Corrugator | January – March 2013
Digital Printing for Corrugated Boxes The process of transferring ink to the corrugated box has evolved through the years with newer technologies always replacing the older methods and equipment.
Sundeep Munot
Printing on corrugated was limited to relatively simple graphics for most of the 100 years of the existence of corrugated packaging. Changes in the way goods are marketed in recent times have pressured corrugated box manufacturers to expand their print capabilities to enable the printing of more sophisticated images. Point of purchase retailing has resulted in the need for corrugated packaging to expand its role from that of just being a shipping container to also act as a selling tool at the retail level.
The methods of printing on corrugated board can be defined in four categories. l Post print (Letterpress, flexo-graphic
and silk screen are the process used in post print.) l Pre print ( Flexo , Roto Gravure) l Litho lamination (Offset) l Digital. Post-print has been and remains the dominant technology for printing corrugated containers. The term refers to the fact that the printing step occurs after the linerboard and medium have been combined to form corrugated board. Great care must be taken in post-print not to crush the flute structure during printing. Skill is required by the machine operator to regulate the pressure of the blank to the printing plate in order to achieve a quality printing job. Letterpress, flexographic and silk screen are the process used in post print. Preprint involves printing the linerboard before it is combined into corrugated board. In this process a roll of linerboard is unwound and printed on a printing
press and then is rewound into a roll to be made available to the corrugator. This rollto-roll printing process occurs in one pass through the printing press. The advantage of preprint is that printing pressure is not an issue. The linerboard is passed around steel rolls, which act as a solid backup to the linerboard during printing. This system takes the worry of too much pressure out of the printing equation and allows very sophisticated photographic quality printing to be achieved on corrugated. The only drawback is that for this method to be economical a large volume of boxes is needed. Another method which has allowed more sophisticated images to be displayed on corrugated, employs the lithographic printing process. The method involves printing a sheet of publication grade paper on an offset printing press and then laminating the printed sheet directly to the corrugated board, or a finished box. Another way lithography is used is known as single face lamination. It involves laminating the printed sheet directly to the medium as the outside liner. Litholamination generally produces the most
sophisticated form of printing for relatively small packages for the consumer market. Digital printing is the newest method of printing on corrugated and is still in its infancy compared to other methods. Digital printing basically uses inkjet printing technology, but adaptations allow
it to print on a larger scale, print thicker substrates, and the inks are formulated for linerboard. Graphics from a digital computer file are transmitted directly to a printer that plots the graphics onto the corrugated board. The need for printing plates is eliminated, however because it is a time consuming process it is used primarily for short runs.
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74 | The Corrugator | January – March 2013
Digital Printing on Corrugated and Other Substrates – 1. No Tooling Required - Ideal for small runs. 2. No minimum order quantity. Many times we leave valuable orders looking at the high development costs of designing, positives, offset plates and die’s. Digital press and cutting table eliminate the need for printing plates and cutting dies. Eco-friendly, water based inks provide a vibrant, eye-catching image. In this jet age time is an important factor. Digital corrugated printing is ideal for those projects requiring fast turnaround and quick service.
Digital Corrugated Printing is perfect for: l l l l l l l l l l l l
l l
Seasonal & Time Sensitive Promotions Trial Runs New Product Launches Exhibit Booths Presentations Samples Signs Specialty Jobs PDQ Displays POP Displays Counter Top Displays Over-sized Displays and Packages Models Shipper Trays Retail Posters
Can also print on: Corrugated Plastic l Foam Board l Gator Board l Polystyrene l Jet Mount l Acrylic l Glass l Wood l Tiles l Aluminum composite sheet Digital Printer Benefits: l
l l
l l l l l
l l
l l l
l
l
Double-Sided Printing No tooling (printing plates or cutting dies) required Efficient short runs Fast reaction times No minimum order quantity Reduced warehousing costs Eco-friendly water based inks for packaging in the food industry and indoor use True 600dpi High Resolution Graphics utilizing 4 color process (CMYK + LC, LM). No limit on colors Vibrant Image UV Coating available Cost-effective short runs of high quality output Oversized (63” x 121.5”) and 3D display Media thickness up to 12mm thick
A hybrid technique usually is a combination of two different technologies or processes and it can add great value to both packaging and product. Conventional and technologies have characteristics.
digital very
printing different
Flexographic print: It uses static printing forms to reproduce printed matter. The merit of this kind of printing technology is inexpensive and gives very good print quality in post-print depending on the substrate surface quality.
Digital print, such as inkjet print: It implies that graphics are printed directly from a data file. The aim of this technique is to achieve high quality at high speed when printing customized data on packages made from paperboard.
Digital Printer for small Run Jobs Let me quickly brief you on the digital converting & finishing 1. Reduce Proofing Cost – Soft Proof an entire box 2. Decrease Operator Errors 3. Artios CAD allows us to easily create PDF files and send a number of rough designs 4. The entire process cuts down on approval time 5. Customers are very impressed with the 3D renderings 6. The rotating 3D PDF files and new project functions have proved to be very helpful this creative process and make possible for extremely quick decisions…” 7. Overall gain in quality and reliability while significantly reducing our cost 8. Enormous amount of time is saved very effective Create new and unique designs in seconds from scratch or by using the extensive library of folding carton and corrugated styles. You can create reusable designs
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76 | The Corrugator | January – March 2013
using simple drafting tools. Integrate graphic design files into the CAD design file. Vectorize edges in any graphic to produce an outline around elements in the image.
Digital Solution for Designing & Cutting Creasing 3D DESIGN Powerful 3D design tools enable quick folding of the final folded design for even complex designs with curved creases. Control fold angles and mating of multiple design elements for quality control inspection of folds, tucks, flaps, inserts and fitments. Visualize the assembly and folding sequence of designs, create assembly instructions and assembly animation movies. Create 3D models of primary product such as cans, bottles, glasses and bags. Create exact fitting packaging around imported 3D models or 3D models created directly in Artios CAD.
Cnc Cutting Creasing / Flat Bed X & Y Cutter Creaser Esko IX L 44 IS A Flat Bed X & Y Cutter Creaser, It is a Sample making and shortrun production table with working Area: 87 x 120, max Sheet size :90 x 135” It is a die-less cutting and creasing table for packaging.
Unbelievably it is a complete tooling family that enables quality processing of materials ranging from thin cartons to the most demanding heavy-duty materials such as triple-wall corrugated, wood and acrylics. This is just an example of how latest technology helps us to develop a packaging tool for our customer with all graphics, colours and shapes without spending much on development cost.
This article was first published in Industry Insight - the quarterly magazine of WICMA. July-Sept. 2012, and is reprinted here with their permission.
The Corrugator invites original Articles along with appropriate photographs Please send your editorial contribution to The Editors….
Federation of Corrugated Box Manufacturers of India E-mail: admin@fcbm.org
The Corrugator | January – March 2013 | 77
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
78 | The Corrugator | January – March 2013
Full colour flexo in-line printing on corrugated board – An Interview
We recently attended Mahesh Kode’s technical presentation at the FCBM conference in Mumbai where there was qu bit of discussion about increasing the quality of corrugated box manufacturing and adding value with full colour flex printing in-line essentially what is called the corrugated post-print process. After the event, Naresh Khanna took the opportunity to fine tune his understanding by interviewing Kode who is the manager - sales technical and marketir DuPont Packaging Graphics South Asia. PSA - Is it true that flexo printing on corrugated is much bigger than most people realize? Mahesh Kode–This has to be looked at from the right perspective, and the interpretation also needs to be altered slightly. The narrow-web flexo segment (mainly pressure-sensitive labels, wet-glue labels and some lamitube printing) as well as the CI-flexo wide-web industry (for milk and edible oil pouches, diaper packs and feminine care products) are well-defined in the organized sector, hence more clearly captured and reflected in terms of sales numbers. A large part of the corrugated industry, on the other hand, still falls in to the unorganized cottage-industry sector, hence the exact penetration and extent of flexo in this segment is not as clear. As far as our product-portfolio goes, only about 20% of our plates are estimated to cater to the corrugated box segment in India-typically consisting of thick plates —2.84mm and above. This is quite different from market like China or the Asean countries, where flexo plates for corrugated forma major chunk off flexo-plate consumption. There are several reasons for thisFirstly, these countries produce and export a large quantity of toys, low and high-end white-goods, fruit-cartons, and other products compared to India, which
laminated to the rest of the board by using a sheet-fed process (pre-print process). Everywhere else, corrugated post-print has evolved wherein the entire board was manufactured on an automated line, and the fully-formed board was then directly printed by flexo Mahesh Kode, sales technical ard marketing of DuPont Packaging Graphics South Asia. Photo: PSA in multi-colour. The latter process enabled higher strength corrugated boxes due to automated corrugating lines, and of course, when you have to print on such an undulating surface without crushing the fluting or compromising on box-strength, flexo is the only way to go! Thirdly, the fact that corrugated packaging was only looked upon as “Big, Brown Boxes,” just a means of secondary packaging to protect and transport, which is now fast-changing!! PSA - What are the new developments in flexo for corrugated boxes?
transited from a primarily agriculturebased economy directly to a current tertiary services-dominated economy driven by sectors like information technology and business process outsourcing. To an extent we have skipped the secondary phase of being manufacturer-exporters. Thus the need for high-quality corrugated boxes never really evolved for the packing, transport and export of small goods.
Mahesh Kode—As above, Indian board and box-manufacturers are realizing that automated corrugating lines inherently make better quality corrugated board with superior strength, in one shot in shorter time without the need to separately laminate the top liner, apart from the work in progress issues of drying. The advent and availability of Chinese equipment at a fraction of the cost of European lines has made them feasible for Indian manufacturers. This includes both, the corrugated board- manufacturing lines as well as the printer-slotters to directly print on the fully- formed board by flexo.
Secondly, printed corrugated cartons in India have continued to be dominated by the pre-print (litho laminated) process, wherein the top-liner was off line multicolour offset printed at prices competitive even with China, and then
Meanwhile, the demand for better quality graphics, multi-colour printing, largeformat is going up with big white-good manufacturers such as refrigerators, television-set producers wanting sharp, two or more colour print on all 4 sides of
Mahesh Kode, El DuPont
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Contd. on page 79 the box over the entire available display area. The rapidly-proliferating mall-culture is spawning the usage of printed corrugated boxes as an advertising medium and brandawareness. This requires digital plates, full-size imaging and plate-processing equipment. PSA - Is it correct that the idea of flattop dots was originally meant for corrugated carton printing and what are the advantages of flat-top dots for corrugated? Mahesh Kode—This is in factverytrue. When trade-shops and flexo-printers in the USAstarted converting all theiranalog plates exposed through negativefilmsto digital plates exposed using a black LAMS layer integral to plates imaged on a Cyrel Digital Imager (CDI) asfar back as 2005, they hit road-block applying this technology to corrugated post-print applications. The wash-boarding effect (where the ribs within the corrugated board became even more apparent and distorted the print with a banded effect) with digital round-tip dots worsening the fluting-effect compared to analog flat-top dots! The solution came in 2008 when, we introduced DigiCorr, wherein aflattop dot could still be produced whilst remaining in the digital workflow without the use of films or lamination or special lamps, by exposing the imaged plate in an inert atmosphere. This was made possible by the use of a gas-chamber in our exposure device for eliminating the oxygen. The presence of oxygen retarded polymerization at the dot-tip, causing it to be rounded while the introduction of an inert gas enabled complete polymerization ofthe dot-tip, making it flat-top dot. This helped get rid of the wash-board effect even while using digital plates for flexo printing directly on corrugated board. PSA —How do you see the quality of corrugated printing improving? Do you really think 4- colour printing on corrugated is coming and if so how fast? Will this always require white or bleached kraft liner or can if be done on natural kraft with any reasonably useful results?
Mahesh Kode -The quality of corrugated printing is evidently improving - look at the sharp, crisp printing on white-goods, beverage and other FMCG cartons. The reason that this is being driven is that fact that these companies realize that the function of the box is no longer only to protect, but to serve as a POP pointof-purchase display device, whether in transportation, on a mall shelf, floor, or delivery! Full 4-colour process printing on corrugated is still in its early stages, with Chinese presses starting to come in, but not all configurations are suited for multi-colour halftone printing. Process colour printing has to be done on white or bleached kraft paper to bring out the best results. India is perhaps the only country where liquor, beer and bottled water cartons are still offset printed and then laminated off line. This will change to follow world-standards.
Our DigiCorr technology is now available in India to tap the benefits of digital flat-top dots without any additional steps, or film lamination or special exposures during the plate-making process, and with the threat of negative films cost and supplies becoming increasingly real, printers and plate-makers can move away from analog plates. They can avail the benefits of digitalisation without compromising on the wash-board effect in this very promising industry now coming of age in the country!
PSA - What are the considerations for specifying flexo plates for corrugated. What are the appropriate thicknesses and other possible things that a corrugator should request or ask for? Mahesh Kode - More than plates, it begins with the press specifications itself! We have come across several printers who have installed a 3-colour press wanting to do both, line and halftone work, without realizing that the ani loxes required for both applications are completely different. And unlike label or CI-flexo presses, these aniloxes cannot be routinely interchanged - the presses are designed to use the same original anilox all the time. Hence the corrugated box-manufacturer has to decide beforehand which segment and configuration he will go in for, or whether he needs two separate presses to address both requirements. On plates it drills down to using thinner plates for all the obvious advantages of sharper print and better handling. Hence we encourage printers to use 4.7 mm thick plates from the previously used thicker ones for corrugated print and to compensate with a thicker sticky-back (double-sided adhesive tape).
Source: Jan. 2013 Packaging SouthAsia ‘Reprinted with permission from Packaging South Asia www.packagingsouthasia.com.
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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.
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84 | The Corrugator | January – March 2013
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86 | The Corrugator | January – March 2013
“We Plan to bring in R & D facilities in India and make it one of our research hub for packaging” – An Interview
Says John Luke Chairman and CEO, MeadWestvaco Corporation (MWV). In conversation with Mahua Roy, he reveals his big plan for India and highlights promising innovation area for packaging solutions, What is your market portfolio in India? We see significant opportunities for higher quality and more innovative packaging solutions in corrugated or industrial markets, as well as many consumer categories such as food, beverage, healthcare and personal care - largely due to the emergence of modern retail and a fast-growing middle class in India. We are starting to see evolution in rigid packaging in the country. It is being adopted rapidly, thereby replacing flexible packaging in many traditional product categories such as cookies, crackers, biscuits, snacks and few homecare products too. In Pune, we have our manufacturing unit. Our corrugated packaging solutions mainly go into the agricultural markets, i.e. packaging for fruits & vegetables that help in their hygienic transport from farm all the way to market. Our solutions are aimed at industry and supply chain - ready to be competitive in this rapidly developing scenario in India.
Besides, we are also excited about our caps and closures portfolio. With the growing demand for convenience, caps and closures call for renewed innovation. Items such as ketchups, condiments, etc have huge scope of absorbing this innovation. It is imperative to upgrade packaging, making it consumer-friendly.
What has been the status of corrugated packaging in India? The industry as a whole is served by par quality packaging. This greatly brings in the need and acceptance for high-quality packaging. It is necessary for the industry to realise that packaging one of the most important parameters reduction of spoilage and waste.
How do you view India as a business destination? We are enthusiastic about the opportunities in India. Even though overall GDP has been growing at a slower rate in the country, if one looks the broader canvas, there are huge opportunities in packaging. It can be rightly said that no place in the world booming in economy as India. It is an attractive market and we are excited about expanding in India. If you look at the figures, in India, per capita packaging consumption is $ 10, whereas in its contemporaries China and Brazil, it is $ 40 and $100 respectively. In the US & UK, it is way ahead, $ 400. This shows the underpenetration of packaging in the country, which can
John Luke - Chairman and CEO, MeadWestvaco Corporation (MWV). translate into huge opportunities. We plan to invest more in consumer & supply chain research. We are now in the process of turning them into solutions in the market. In course of next three years, we plan to bring in R&D facilities in India and make it one of our research hubs for packaging.
What are your priorities for the Indian market? Our first priority is around executing integration and expansion of Ruby Macons, given how important a stepping stone that acquisition is in our growth strategy. At the same time, we are looking at more than doubling the capacity of our businesses in the country. This not just includes scaling up the manufacturing but also expanding our presence in the relevant marketplaces. We aim at capturing the latent demand and essence & needs of the consumers in the industry, which calls for much higher quality. Apart from making our innovations consumer-friendly and attractive, we are also aiding the demands of brands. Brands can benefit greatly as they can enhance promotional features on the packaging.
What are the areas of innovation for corrugated packaging? One of the most common observations across retail stores is the presence of
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88 | The Corrugator | January – March 2013
for fruits. We plan to replicate this model in India and have invested greatly in primary research. Using corrugated packaging solutions will prove to be a better alternative to the current practice of loading directly in trucks or wooden crates. Rotting food contributes largely to greenhouse gas emissions and good packaging solutions can help combat this global problem. We are looking at sustainable solutions to use lighter materials and downsize the amount of packaging.
dented or damaged corrugated packages. Research shows that around the world, consumers reject externally damaged packages. It affects the brand image directly. There is great potential on this front to enhance strength of packages. Also, there is a growing need to increase strength in tertiary packaging to withstand harshness of supply chain. Besides, bringing in good printability to help product stand out on the shelf is another area of innovation.
One of things we learnt in Brazil was the emphasis on reducing wastage. So we concentrated on developing products for the agricultural sector to reduce the substantial transit related damage of fruits and vegetables. We developed a packaging solution where fruits can be placed in an innovative package and then loaded in an organised manner. Virtually all of it made it to the market unscathed, and gradually contributed to make Brazil a net exporter
Courtesy: Modern Food Processing, February 2013
This is reprinting of an interview with John Luke by ‘Modern Food Processing’. Our sincere thanks for their permission
The Corrugator | January – March 2013 | 89
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Single facers also available in finger type economic models from 1200 upto 2500mm widths in electric, hot oil and steam heating system.
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
AUTOMATIC CORRUGATED PAPERBOARD PLANT
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)
92 | The Corrugator | January – March 2013
Inventory Management What is inventory? Inventory is an idle stock of physical goods that contain economic value and is held in various forms by an organization.
There are three main parts of inventory 1. Raw material i.e. Paper, Gum, Stitching wire, Binding cloth. 2. In-process material i.e. Printed papers, Liners, Sheets. 3. Finished goods i.e. Boxes.
What is meant by Inventory management? Managing the Inventory at your end to avoid stock out in manufacturing & dispatch process while incurring the minimum. Inventory carrying cost.
Why to keep inventory in control? 1. Inventory costs money. If we buy RM & keep without converting it at our end, is of no use. Our supplier will ask for payment on their due dates. Beyond that we have to bear interest cost of financier / Bank. 2. It occupies space in our factory, which if freed can be used for some other productive purpose, generating revenue for us. 3. Excess inventory creates wastage. We will not be careful about the wastage or avoiding it will be beyond the control.
4. Excess manpower will be required for shifting material. 5. Chance of theft, pilferage and shrinkage increases. 6. Its quality may deteriorate over a period of time 7. It can also become obsolete 8. Less inventory means less money blocked in stocks, which in turn will improve your in time paying capacity.
Why to keep RM inventory? Meet variation in Production Demand. Cater to Cyclical and Seasonal Demand. Economies of Scale in Procurement Or Minimum order qty / Packing size. Take advantage of Price Increase and Quantity Discounts Reduce Transit Cost and Transit Times. Long Lead and High demand items need to be held in Inventory.
Why to keep Finished Goods i. e. Boxes inventory ? Because customer wants us to keep it at our end ready. Now a days, all our customers want material Just in Time. That means they want to reduce there inventory of RM for them. So what they do is they give us order, give us schedule or ask us to keep boxes ready for dispatch. If we keep boxes ready for dispatch but do not dispatch, then our inventory goes up and customer’s inventory goes down. Can we do same thing with our suppliers ? Just give it a thought and interact with suppliers.
To meet the customer’s urgency. Some customer or purchase personnel has a bad habit. They do not plan their requirement in day time and during night at around 8.15 pm, will call us & say that
Anil Loya M/s. Akanksha Packs, Aurangabad.
he wants so and so material in morning. How to do that? I will not be able to start production before tomorrow morning and will take another day for supplying. At that time our finished inventory is useful to us.
To encash the sudden requirement in market. Let us suppose there are three suppliers to a customer. I keep extra boxes ready, so that in case any other supplier fails, I can supply that much extra to them. The dispatch quantity is less than our Economic Production Lot Quantity. Customer gives us order of 5000 boxes, but ask us to supply 400 nos alternate day, then to meet daily requirement, we produce the boxes & keep on supplying for the next 10 days.
Cost of Inventory : 1. Ordering Cost: Cost of procurement and inbound logistics costs form a
The Corrugator | January – March 2013 | 93
A leading Name in Corrugation Heating Systems
11mm and 13.5 mm Straight, Tubular and Zonal Heating Systems Our experience of 30 decades in heating industry help us to understand your heating requirement/ problem and give us edge to offering you a perfect solution for heating & electricity saving.
ZONAL HEATING SYSTEM Saving of Electricity Consumption Easy to install and easy to maintain No need of separate machine for small and big sizes thus a big saving in small investment
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Reduce in wear and tear of machine by avoiding unnecessary heat
Temperature controller helps in reducing electricity consumptions & wastage by automatically switch off the heater after reaching at desired temperature
TUBULAR HEATING SYSTEM
Corrugated Box Drying Machine
Insulated with Magnesium oxide Powder
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Insulated powder is compressed by swager for long life Tube used are SS 304/SS 321/Incloy tube
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94 | The Corrugator | January – March 2013
part of Ordering Cost. Ordering Cost varies based on two factors - The cost of ordering excess and the Cost of ordering too less. 2. Inventory Storage Cost: Inventory storage costs typically include Cost of Building Rental, Facility Maintenance and related costs. Cost of Material Handling Equipments 3. Cost of Carrying: Includes the costs of investments, interest on working capital, taxes on inventory paid, insurance costs and other costs associated with legal liabilities.
Standard Methods of Inventory management : 1. The supervisor or manager is the supremo on shop floor. He knows each and every item lying on shop floor. [This is what we assume]. He, based on his memory and intuition, gives order for paper / material. 2. Some one goes and physically checks the size & stock that is required. Based on that gives the balance requirement. 3. Where ever the stock records are being maintained either manually or computerized, gives the stock at fingertips and balance requirement is decided.
How to improve on inventory management 1. Maintain Inventory turnover ratio. It is sales / average inventory. Some people may take cost of goods sold / value of average inventory. Inventory ratio should show rising trend. 2. For particular type of material and different supplier, there is different lead time. Based on that and your consumption pattern, calculate the reorder level. As soon as your stocks reaches the reorder level, It is to be ordered immediately. This will avoid excess material as well as shortfall of material. 3. If you don’t have a small requirement of particular size but have a larger size,
then you may calculate the wastage cost vs. new material ordering cost. By thumb rule if you have size more than 42”, then you can discount your inventory by 1” per month. And for smaller size you can discount it by ¾” per month. For higher BF material 42 will be replaced by 38” 4. You should have RM requirement planning system. Exact requirement should be calculated by system for particular period’s requirement and then we may add buffer stock and order accordingly. You may use software available in market or in simple excel sheet , it can be worked out. 5. Order only material that is required by us for production. Avoid ordering excess material in anticipation of order or anticipation of price rise or for deckle adjustment. 6. Send formal PO mentioning rates, Qty. and date of delivery. You may follow up with suppliers based on PO. Ordering double material will be avoided, and surprisingly you will notice that many times supplier supplies material as per his convenience and not as per your requirement. At the same time, supplier will not supply you excess material i.e. 4 tons in place of 3 tons required. Or any non-order material to suit his deckle. 7. Schedule the order in distributed delivery time. If you buy weekly/ fortnightly material, it will help in reducing the inventory. But for this, either you have to have higher quantities or you can buy from local paper mills. 8. Try to locate and develop the nearby suppliers. 9. Consume the material by First in First out method. Here we have to take little pain. When we receive fresh material, first remove old material from place, put new material and above or in front of that put old material, so that the old material will be consumed first, else we will land up in quality problems of old gum, rusty pins and low BF reels.
10. Now a days, quite a high speed machines are available. They will reduce the production lead time. It will reduce our in process as well as finished goods inventory. You might have observed that many huge quantity box consumers prefer to buy material from automatic plants; it is because of immediate supplies of boxes in huge quantity.
Inventory Audit: Inventory Audit is to be carried out on monthly basis. In audit, One should check for 1. Is there any old stock lying for more than a particular period & why? 2. For what purpose the old stock was bought & what is the status of that purpose? 3. Should we continue to hold the inventory further for same purpose or other? 4. If not, what is the alternative use of it or disposal is required? 5. What ever stock of material bought latest, lying in inventory, is it as per requirement or excess in quantity? 6. Inventory reconciliation - involves reconciling physical inventory at site with the system inventory.
Anil Loya has worked with different organizations like Bajaj Auto Ltd,, Piramal Group, Gabriel India Ltd, Endurance Systems [I] Pvt. Ltd., Videocon Industries Ltd, Varroc Lighting Pvt. Ltd. In Production, Planning and Materials dept. for 11 years Since last 11 years he is in corrugation industry. This article was first published in Industry Insight - the quarterly magazine of WICMA. July-Sept. 2012, and is reprinted here with their permission.
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Product Profile Strapack RQ-8 Strapping Machine The Strapack RQ-8 strapping machine is innovatively designed for high output operations. There are many different arch sizes available which allow for this Strapack model to effectively strap a variety of products. The plastic strapping automatically feeds through the arch which provides for high output operations. The operator presses either a button or footpedal and the plastic strapping is automatically tensioned and sealed around the product. If you want a highly automated production line to maximize productivity, the Strapack RQ-8A is recommended. The reliability, speed, ease of operation and low maintenance costs of the RQ-8 strapping machines are now available on a bundling machine designed specifically for the corrugated industry. The RQ-8CR/FB features a high cycle speed, easy strap loading, auto re-feed and loop ejection, lubrication free operation and safe dual tensioning. It incorporates a 1650mm x 500mm (65” x 20”) arch, top compression, variable speed conveyor and
without being injured due to their unique corrugated cartilage structure that separates the beak from the skull. The Kranium cardboard helmet exhibits a similar design structure; the bicycle helmet is able to flex and withstand impact because of the Dual Density Honey Comb Board it is made up of.
runs 5mm or 6mm (1/4”) strap to facilitate the requirements of corrugated container production. For production settings with high output requirements, the RQ-CR/FB is now available with a dual strap dispenser and automatic strap coil transfer system. This newly developed system is designed to prevent any costly production stoppages due to strap coil changes. The model RQ-8CR is also available with a driven roller conveyor table. Model RQ-8CR/FR, shares the same robust design and performance enhancing features of the RQ-8CR/FB with the added flexibility of a powered roller bed.
Kranium Cardboard Helmet Revolutionizes Head Safety An Indian student from the Royal College of Art has designed a bike helmet that’s constructed entirely from cardboard. While the cardboard helmet is about 15% lighter than conventional ones, it can take thrice as much impact from a collision. Besides being eco-safe, it has a water proof coating for keeping out rain and sweat. Anirudha Surabhi, the Indian designer, drew inspiration from the woodpecker while designing the helmet. Woodpeckers can repeatedly strike firm wooden surfaces
Force India, the Formula One team will incorporate the Kranium helmet technology into its very own helmet design. Source: Internet
GCU Smart Flex An Innovation by Signode The innovative GCU SmartFlex™ compresses and straps corrugated loads utilizing a modular head design for easy maintenance and operation. Accommodating up to four heads in five positions, the GCU SmartFlex provides more strap placement options, improved single stroke capability and higher throughput to maximize production.
Features MHC Modular Strapping Heads Easier to operate — Constructed with few moving parts and durable wear parts, the MHC strapping head modules are far
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98 | The Corrugator | January – March 2013
Durable, steel construction
Designed as an affordable and precision micrometer, the unit is available in two models:
Durable steel construction provides long-lasting operation. The conveyor is incorporated into the frame and added outer rails to increase machine stability and create a more compact footprint. Conveyor rollers lift out easily for cleaning
Features:
or repairing.
l
l l
49 – 76 / 77 Thickness Tester Two new precision micrometers introduced by Testing Machines Inc.
more cost efficient to maintain than other strapping heads. MHC strapping heads feature a simple design with no belts, pulleys or adjustments.
The latest innovation is the model 49-76/77 thickness tester. The NEW model 49-76/77 incorporates a robust mechanical design and features a proprietary electronic measurement system which produces extremely stable zero control and maintains perfect calibration.
l l
Shrink Wrapping Solutions for Corrugated
DAMARK machines fall into four categories; combo L-sealer and shrink tunnels, semiautomatic shrink wrappers, automatic shrink wrappers, shrink band tunnels.
Equipped with Allen-Bradley PLC, the control panel placement reduces the machine dimensions for easier integration into varying production lines.
DAMARK’s in manual, feeds. All L Sealers,
Strap placement flexibility
The strap feeding modules are mounted directly onto the dispenser framework, enabling simple one-step loading and feeding. Feeding and clearing can be done without entering the machine, minimizing downtime and operator interference.
l
PLEXPACK is a well known manufacturer of Damark Shrink Packaging Equipment.
Standard electrical controls
“Smart” Dispensers
l
PLEXPACK manufactures a wide range of DAMARK Shrink Packaging L Bar Sealers and Shrink Tunnels.
Less downtime — Separate, lightweight feeding and sealing modules, weighing less than 35 lbs. each, are easy to access and remove for maintenance, drastically reducing downtime. Heads can be accessed and removed from the floor without the use of special equipment.
Innovative head spacing with five positions provides for variable strap placement options and minimizes the need for double stroking, resulting in improved flexibility and faster throughput of up to 200+ loads per hour. Head spacings are available at 8”, 16”, 24”, 32”, 40” and 48”.
l
Large digital display Auto zero Two measurement ranges: 0.0000-1.2700 mm or 0.000-12.700 mm Special anvil diameters and dead weight loads available Calibrated gauge blocks (available, for instrument verification) Motorized auto cycling Imperial or metric units Serial port
shrink wrap machines come automatic and semi-automatic the equipment, including Shrink Wrap Tunnels, and
Unlike conventional thickness testers available today the 49-76/77 does not use adjustment knobs or potentiometers to adjust settings. The unit features a onetouch auto zero and a PC controlled calibration routine. The 49-76/77 can be configured to meet various international specifications and test standards for different types of materials including corrugated, plastic film, paper, tissue paper, nonwovens, textiles and other sheet like substrates. Contd. on page 103 The Corrugator | January – March 2013 | 99
From Reel Stands and Single Facers to Automatic Plants we offer a range of hi-speed, hi-performance machines for Box Makers. Our Automatic Plants are successfully installed in India at: Delhi, Mumbai, Goa, Pune, Kolkata, Bangalore, Baramati and other places.
SF - 320S(360S) Fingerless Type Single Facer
ZJ-VG Hydraulic Shaftless Mill Roll Stand (Heavy type)
NC Computer - Control Rotary Cutter for 2 layer
2200mm - 7 Ply Automatic Plant
www.xinguangmachinery.cn
100 | The Corrugator | January – March 2013
Making a strong presence in India
12 PRODUCTION LINES INSTALLED IN INDIA
XG-G Series High-Speed Printing Slotting Die-Cutter
SF-380S (405S) Fingerless Type Single Facer
SF-405M Multi-Cassette
HEBEI XINGUANG CARTON MACHINERY MANUFACTURE CO., LTD.
Add: Dongguang Country, Cangzhoucity, Hebei Province, China. Tel.: 0086 - 317 - 3074777 | Fax: 0086 - 317 - 3074666 | Business Mobile No.: +86 138535 89877 | 139 03170809 Email: xinguangmachinery@yahoo.com.cn India Service Office : Xinguang carton machinery – China (India Division) Plot No. J-54, M.I.D.C., Tarapur - 401 506. Boisar Maharashtra. India | +91 93228 14385 | E-mail: kapil@xinguangmachinery.in
Service Centre in Mumbai with 2 Chinese Engineers
www.xinguangmachinery.cn
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102 | The Corrugator | January – March 2013
Contd. from page 99 Heat Shrink Tunnel Ovens come with electronic controls for accurate sealing and shrinking. PLEXPACK also manufactures custom L-sealers used for oversized products and parts such as window panes and garden lattice. Plexpack Corp. the Damark shrink packaging equipment manufacturer offers shrink wrapping solutions for an array of corrugated applications including pizza boxes, egg cartons and drink tray bundles, shrink wrappers, shrink tunnels and full enclosure style shrink wrappers. Source: Internet
Diecut UK introduce the Goldline “The new Diecut Goldline is a manual die-cutting system which truly replaces the hand fed platen. It cuts everything from paper, plastic, corrugated board, box board and display board, foam ex, and kiss cuts etc. ‘Everything on this machine has been developed around safety and production This is the biggest development in over 90 years of manual die-cutters. The manufacturer claims that this machine is a true replacement for the hand platen whatever your size requirement may be.
The range of new machinery from Diecut U.K. includes: l
Diecut Whiteline fully automatic range for the corrugated industry; l Diecut Redline flexible semi-automatic die-cutter capable of feeding every type of substrate; l Diecut Greenline range of hand fed platens; l Diecut Goldline range of manually fed platens.
This is how the machine works: Feeding / Delivery Section Operator places sheet on to fat cutting plate which shuttles into the press section is diecut and then delivered out. The operator repeats this process, the benefit of feeding on to a flat surface. Compared to a trafitional clamshell platen at a angle is significant - giving up to 10-15% more production.
Diecutting Section Electronic pressure setting reduces make ready times. Powerful press section delivering up to 500 tons cutting pressure. On machines up to 1500 the tooling comes out of the front machine for easy make ready and job changeover. In all larger machines the tooling comes out of the rear of the machine allowing the operators to make ready.
Machine Features Designed with safety in mind, the machine is equipped with light guards at all possible trap points. Due to the design the operators do not need to gain access to the inside of the machine or sit on a moving bed like on a traditional handfed platen. Job changeover is hazard free.
Experience the cost savings and extended bearing life NyeCorr 140 is manufactured by Nye Lubricates Inc. which is headquartered in Fairhaven, Massachusetts. NyeCorr® 140, a high-temperature PFPE/ PTFE grease for single-facer bearings, is being used by over 200 corrugating plants worldwide. NyeCorr 140 is completely compatible with DuPont Krytox® 226 and 227 and can be installed into bearings currently packed with Krytox with no problems whatsoever. Nye Lubricants, Inc. of USA formulates, manufactures, markets and sells highquality synthetic lubricants, thermal coupling compounds, and index-matching optical gels. Their product development process is consultative, focusing on the customers’ performance specifications and cost and warranty requirements.
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104 | The Corrugator | January – March 2013
NyeCorr 14 is the most advanced PFPE Lubricant available to the corrugating industry today, and it’s also the most environmentally friendly.
It offers the following advantages: Higher Oil Viscosity * Means thicker film of oil * Means less bearing /race contact * Means less vibration and wear
Eliminate Corner Damage due to strapping with BanderFelins Ultra-Sonic ATS US 2000 The US-2000 machine is designed for heavy use applications. It seals using an ultrasonic weld. The digital controller offers precise adjustments, fault indications, soft tension, fixed length, multiple languages, diagnostic and statistical tools, and password protection as standard features.
The design of the feed track and arch makes it easy to access. Daily maintenance and cleaning can be done by an operator rather than a technician. The machine is ergonomically designed with an adjustable working height of 30”- 39”. The US-2000 machine can be customized for nearly any application. In addition to the standard options of arch size and band width, the machine can also be customized to include an automation interface signal, compression cylinders, custom fixturing, program memory and much more
Lower Evaporation = Longer life * Same chemistry means no roll change * Better corrosion package means less rust * Cost less means you can reduce maintenance
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106 | The Corrugator | January – March 2013
The Corrugator | January – March 2013 | 107
INDIA STAR 2012 AWARDS National Awards for Excellence in Packaging India Star is the only National Award in India and officially recognized by Asian Packaging Federation (APF) & World Packaging Organisation (WPO), Many of the Award winning entries competed for WORLDSTAR & ASIASTAR. The highest nominations received this year for ASIASTAR 2012 & also WORLDSTAR 2012 contest across the globe by any country is none other than INDIA. Some of the India Star 2012 Winners are featured here
Winner: Jayna Packaging Pvt. Ltd.
Asin paints Tool Box Pack Box in the shape of tool box looks different and perfect shape for the target market, which is creative.
Mail - Order Pack For Shirt Stiff Collar The pack is a tamper evident box with a 3-ply heavy duty corrugted box.
Naturolax Gynic Pack Unique Barrel Shaped box made form corrugated board which has a natural corrugated finish, and attractive locking arrangement. Delegate pack - zero degree 4 ply corrugated die - cut box was designed with carrying handle and a shoulder strap for the participants / delegates.
108 | The Corrugator | January – March 2013
Corrugated display for PENTEL Corrugated display created with 24 compartments. it is made with (3ply) corrugated board.
Single Piece Box For Camera Stand 4 ply corrugated die-cut box was designed with carrying handle and a shoulder strap for the participants / delegates.
Winner: KCL Ltd.
Engine Box Termite and fungus free. Safety of the fragile part is taken care. 100 percent biodegradable. Number of product placed has increased from one in wooden box to four in corrugated box.
Winner: Larsen & Toubro
Transport Package This design also takes care of low magnitude shocks & vibration by complementary EPE padding.
Transport Package A speciality wooden pallet is provided at bottom which facilitates easy handling of the heavy product. Honeycomb design gives both protection and cost effectiveness for this product
Winner: Parksons Packaging Ltd.
Minute Maid - Pack This carton is made on Duple board along with E-Flute to impart strength to carton during transit.
Winner: The Himalaya Drug Company
Neem & Turmeric Soap Launched in USA Market Soap product is packed in uniquely designed 2ply E-fluted carton.
Winner: Cel Packaging Pvt. Ltd.
Winner: TPCL Packaging Ltd.
SRCM CD Box One piece carton with no gluing. Formation like a brief case for easy and convenient handling in super markets and airports. It has 3 ply structure.
Packaging for Fine Chemicals in Glass Bottle 2.5 Ltr. Only corrugated material is used Eco - friendly package with UN certification with High level of protection against damage.
Pack for Multiplex XUV large Axle Only corrugated material Eco - friendly package Easy to assemble and handle
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110 | The Corrugator | January – March 2013
Industry News
Suppliers to consumer product companies expand India presence Companies providing packaging or intermediary services to large consumer packaged goods firms are stepping up their investments in the country even as India remains a key market for their customers such as Hindustan Unilever Ltd and PepsiCo India Holdings Pvt. Ltd. US-based MeadWestvaco Corp., a packaging firm, announced a Rs.1,000 crore investment in India over the next three-five years. Likewise, McCain Foods (India) Pvt. Ltd, the Indian subsidiary of McCain Foods, Canada, a supplier to McDonald’s Corp. and manufacturer of packaged ready-to-eat food under the McCain brand, announced a $69 million (around Rs.376 crore today) investment in its potato processing plant in Mehsana, Gujarat. MeadWestvaco’s investment includes the purchase of Vapi-based Ruby Macons Ltd that was announced in November as well as additional plans to expand current production at the facility. “We see significant opportunities for higher quality and more innovative packaging solutions...as well as (in) many consumer categories such as food, beverage, healthcare and personal care -largely due to the emergence of modern retail and a fast-growing middle class in India,” said John Luke, Jr., chairman and chief executive officer, MeadWestvaco. “On a relative basis versus the other markets that we are investing in, India is still one of the most rapidly growing markets in the world,” said Peter Durette, senior vice-president and chief strategy officer, MeadWestvaco.
“The Indian consumer packaged goods industry grew 20-25% in 2011-12 and is currently growing at close to 15%,” said Santosh Verma, director, investment banking, IDFC Capital Ltd, adding that even though the growth rate has come down, it is still high when compared to most other sectors. To be sure, weak consumer sentiments saw volumes drop in the second quarter of fiscal 2013. Analysts expect discretionary spends on packaged foods to remain subdued even in the December quarter. In the past year, Vivimed Labs Ltd, a supplier to Unilever Plc., L’Oreal SA, and Colgate-Palmolive Co. for oral care, skincare, haircare and sun care products also announced investment of $60-70 million. And Galaxy Surfactants Ltd, which caters to requirements of surfactants and speciality chemicals required by personal care, soaps and detergent companies, said in September that it planned to invest Rs.300 crore on expanding its presence in India and elsewhere. In September 2012, US private equity firm Blackstone Group Lp invested Rs.243 crore in Indian fragrance and flavour maker SH Kelkar and Co. Pvt. Ltd whose products are used by consumer packaged goods, pharmaceutical products and dairy products companies.
“India will be the fourth largest packaging power,” says Dr. D. Purandeswari Indiapack 2013 and concurrent International Summit for Packaging Industry drew deeper insights on Indian packaging industry.
machinery suppliers, ancillary material etc of which 85% units are MSMEs. India is at the threshold of explosive growth. Dr. D. Purandeswari, Union Minister of State for Commerce and Industry, Government of India, was the chief guest at the show. She said, “India is the sixth largest packaging market worldwide. The packaging industry is expected to grow at 12.3% CAGR during next 4-5 years to become the fourth largest global market, with sales of $42.7bn.” According to the data available per capita consumption of packaging in India is merely 4.3kg per person per annum, as against Germany’s 42kg and Taiwan’s 20kg, which is very low compared to global standards. Dr. Purandeswari, opined that the challenges that the industry is facing today are lack of regulatory clarity in packaging, consumer awareness towards sustainable packaging and stress towards green packaging materials. The sector-wise break-up of packaging industry in India can be given as follows: processed food packaging is 48%; personal care packaging is 27%; pharma is 6%; and rest is 19%.
Sector - wise break- up of packaging industry in India Pharma Packaging 6% Rest 19% Personal care packaging 27%
Processed food packaging 48%
According to Mr. N C Saha, IIP Director Indian packaging industry has 22,000 firms comprising of raw material manufacturers,
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112 | The Corrugator | January – March 2013
In India the value additions to food products is only 7% as compared to 23% in China; 45% in Phillipines; and 188% in UK. According to a study by Tata Strategic Management Group, the Indian Ready-toEat food market is estimated to grow to $727.09mn by 2015 from the current level of $32.09mn. The growth trend of Indian packaging industry is in line with the global packaging industry. Rakesh Kacker, secretary, ministry of food processing industries (MoFPI), Government of India, said “The food packaging sector grows in tandem with food processing industry, which is surging at 6-7%. This is higher as compared to 4% growth in agriculture sector,” In order to support the food processing sector, MoFPI has launched the National Mission for Food Processing. Kacker said that the scheme aims at decentralisation of issues related to food processing in every state of the country. This would ensure quicker implementations and help the state governments modify the policies as per local requirements. Thomas Schneider, president, World Packaging Organisation, said, “In coming years Indian packaging industry will see a substantial growth. The increasing awareness regarding clean water, safe food and pharmaceuticals will drive this growth. With increasing retail sector, the concept of track and trace devices especially for product identification such as 2D barcodes, radio frequency identification (RFID) etc. will penetrate aggressively into the Indian packaging industry.” Source: Printweek India 10 Feb. 2013
MWV signs a Memorandum of understanding with Gujarat Government. MeadWestvaco Corporation recently announced that it has signed a Memorandum of Understanding (MOU) with the Gujarat Government. The MOU establishes MWV’s investment of Rs. 1000 crore (~ USD 184 million) over a period of three to five years in the packaging
and paperboard industry in India. This investment includes the purchase of Vapi-based Ruby Macons, as well as additional plans to significantly expand current production at the facility with the installation of a new paper machine that will manufacture new paperboard products and grades. The investment and expansion plan is already underway and should yield significant increases in production starting in calendar year 2013. This MOU would support around 800 employment opportunities in the Indian packaging industry. MeadWestvaco Corporation’s (MWV) headquarters building in Richmond, VA Said John Luke, Jr. chairman and CEO, MWV “India is a very important market for MWV, and we are pleased to grow our presence with our acquisition and expansion in Gujarat,”. “We see significant opportunities for higher quality and more innovative packaging solutions in corrugated or industrial markets, as well as many consumer categories such as food, beverage, healthcare and personal care – largely due to the emergence of modern retail and a fast-growing middle class in India. Through the investment we announced today, we are committing to develop globally competitive products that best suit India’s needs – and to bringing the highest standards for environmental and social responsibility to our local operations,” he added. In last issue, we have featured the acquisition of Ruby Macons, the market
leader in corrugated packaging materials in India, as part of the company’s profitable growth strategy, including its emphasis on growth in emerging markets. This investment will expand MWV’s presence in industrial and agricultural packaging in India, which already includes a converting facility in Pune making rigid, humidity-resistant corrugated packaging for fresh fruits and vegetables, consumer goods, household appliances and pharmaceuticals.
Sustainability to Become Packaging Industry’s Top Challenge According to a study done by Packaging World and DuPont, while today’s packaging professional is focused on cost, performance and food safety/security, sustainability will replace cost as a dominant trend in 10 years. Food safety/ security is and will remain a top trend, respondents said. The results from the study by Packaging World and DuPont Packaging & Industrial Polymers reflect the opinions of more than 500 subscribers to Packaging World and foodproductiondaily.com who work for consumer goods manufacturers and converters in marketing and packaging development roles. Food, healthcare and beverage markets ranked the highest, but nearly every industry that uses packaging was represented in the study. Two thirds of the respondents were from Europe, with the remaining from North America.
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There was significant alignment in the views of respondents in Europe and North America, and throughout the results the top trends identified as being dominant today are predicted to change in 10 years. Trends in the second tier tend to maintain the same level of importance.
Here are some of the findings from the study: • Sustainability concerns, ranked behind cost and food safety/security as today’s driving trends, will dominate packaging industry work in 10 years in both Europe and North America. • Cost, today’s top driver, will drop in importance in 10 years. • Food safety/security remains a top factor driving packaging work. • “Right-sizing” packaging in terms of efficient package shape/size, downgauging of package material and minimizing package failures dominate both the North American and European packaging landscapes today. Materials play a critical role in these objectives. • Today’s emphasis on “right-sizing” will give way to strategies to use renewable materials, recyclable materials and smart packaging in 10 years, which is a clear call for innovation and collaboration throughout the value chain. • Though rarely selected as a “top” trend, convenience factors are identified as very important today, and that importance is expected to be maintained in 10 years. • The packaging industry believes consumers will increasingly value recyclability and perceived “greenness” of packaging in 10 years. At the same time, demand for proof of sustainability claims will grow exponentially, for instance in the demand for life cycle analysis data. • Regulations will have a greater influence on packaging design in 10 years, according to 82% of respondents. • Packaging will play a more important role in a product’s success in 10 years, said 81% of respondents.
• Plastics will continue to replace glass and metals, and flexible packaging will continue to replace rigid structures. You can find in a single location the top vendors of EHS management and sustainability software that help you address your sustainability challenges and needs.
Corrugated packaging may play key role to help reduce food waste More packaging not less packaging could help the environment by reducing the amount of food waste going to landfill, according to the Confederation of Paper Industries (CPI) Corrugated Sector. Around seven million tons of edible food ends up in landfill in the UK each year at a staggering cost to household budgets, the economy and the environment. CPI is pleased to confirm that the packaging industry is playing its part in reducing waste with significant investment in preventive steps such as providing easier opening solutions, clearer date labelling and smaller pack sizes. CPI also points to figures released by The Industry Council for Packaging and the Environment (INCPEN) on energy consumption in the food supply chain. INCPEN’s research shows that primary and secondary packaging makes up just 10% of the total energy used in feeding one person for a week, a report on energy usage in the food supply chain) compared to 51% in the production stages and 31% for home storage and cooking. Corrugated packaging is playing a pivotal role in supply chain sustainability by ensuring that more food reaches the consumer’s table as safely and efficiently as possible. Corrugated producers have invested heavily in moving from a brown box for goods in transit to a three-in-one shelf ready packaging solution comprising product protection, an advertising platform and merchandiser. The advantages that corrugated are bringing to the supply chain are a result
of continued investment in printing techniques, allowing greater product presentation on outer packaging which is proving a big hit with retailers. ASDA’s supply chain director, Gavin Chappell, interviewed by The European Federation of Corrugated Board Manufacturers (FEFCO) website, said: “Corrugated packaging plays a crucial role throughout the supply chain from factory or farm to the supermarket and onwards. “Its naturally cushioning qualities, customised information printed on the packaging for easy identification and easy opening improves the flow of products through the supply chain and avoids waste.” Packaging materials to combat food waste are also being developed, with some supermarkets trialling corrugated board that utilises an ethylene-absorbing agent to slow down fruit and vegetable ripening to help them stay fresher for longer. CPI’s Director of Packaging, Andy Barnetson, says that corrugated packaging’s protective qualities are supporting the food industry’s sustainability goals by keeping products fresher for longer, whereas reducing packaging could increase food waste. He commented: “Diverting waste from landfill sites is very important. The Corrugated Industry is proud to use and promote a sustainable and renewable material, over 80% of which is recycled, saving an area of board the size of Greater London from landfill every four months. “Packaging helps to protect food in transit as well as preserving its freshness on arrival at retailers. It also uses far less energy in the supply chain than the production and cooking processes. By preventing food from going off, it is saving far more in resources than those used in the packaging itself. The best environmental solution can be more packaging rather than less. Source: Internet Contd.on page 119 The Corrugator | January – March 2013 | 115
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Contd.from page 115
The Success Story of a Corrugator Recently, something changed the corrugated packaging market in the surrounding areas of Bhopal. This story traces back to April, 2011. Sino Corrugated 2011 There came about 20,000 visitors to Sino Corrugated 2011 Exhibition and 15% of those visitors were from India. Watching a diversity of corrugated cardboard equipment also dazzled the Indian visitors. Some focused on economical equipment and some focused on the equipment with latest technology. Various displays brought different sensation to the Indian visitors using semiauto corrugated machine. However, their targets were to upgrade their production quantity and quality by purchasing suitable equipment and wished to see the benefits within a year. One of the corrugated box owners from Bhopal and his friends came to the stalls. The owner of corrugated cardboard plant from Bhopal realized that he was using semi-auto equipment for the time being. He came to a stall, Max Group, which was combined with many international strategic alliances and was based on Max
Group -Ming Wei & Oranda Company. He witnessed that a throng of visitors both from local China or India and even from the four corners of the world swarming to the stall. Cordially conversing with their exhibitors in English, a language he was familiar with, he learned that they had arranged some customer visits. He was really interested in the automatic corrugating production equipment and determined to take a tour arranged by Ming Wei. He saw the equipment of this company. Although such level of automatic equipment wasn’t new to him, he witnessed the steady production of Max Group -Ming Wei and Oranda’s equipment and their outstanding performance while the machines were running. He also found that design was heavy. The performance of Max Group -Ming Wei/ Oranda’s equipment impressed him the most. Even two of their clients in India were also very satisfied with the equipment.
He decided to invest on automatic corrugated production lines of 1.6M, five plies, the maximum speed of 180M/ Min and equipped with Single Facer, Mill Roll Stand, Slitter Scorer as well as NC Cutter. In May, 2012, after the arrival of goods to the plant, they started installing the machines. His production was four times more than semi-auto equipment. In October, the production was already beyond his expectation. He needed more orders to support the entire production. Nowadays, he has become the supplier with the highest production in Bhopal area. After this customer in Bhopal bought the automatic corrugated production equipment, the printing equipment was not able to meet his needs owing to the incessant production. He also looked forward to positioning himself a corrugated packaging supplier who was able to provide fine printing on high-quality cartons. Utilizing high-quality supply to create added values for his customers, he also created a market segmentation making his competitors unable to get ahead of him with ease. Such slow changing story has influenced the entire corrugated carton supplying ecology in the surrounding areas of Bhopal. This change continues... For more details visit: www.mingwei.com
Global corrugated box demand to rise 3.4% annually through 2013 World demand for corrugated boxes is forecast to increase 3.4 percent per year to 213 billion square meters in 2013, in line with real (inflation-adjusted) gains in GDP. Factors contributing to rising box demand will include growth in industrial activities, particularly the manufacturing sector, which often requires corrugated packaging to protect and transport goods. In addition, ongoing developments in small flute and high-quality graphic board
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will allow corrugated boxes to penetrate traditional folding carton applications, especially in the developed world. Greater interest in corrugated packaging as a point-of-sale display in retail applications will also boost demand for value-added corrugated boxes. However, gains will be limited by the mature state of the corrugated box industry in developed areas such as the US, Western Europe and Japan, where boxes are essentially commodity items used in well-established markets. Corrugated boxes also face competition from reusable plastic shipping crates and other types of plastic packaging. Nonetheless, corrugated boxes will benefit from their environmentally friendly image, as well as certain cost advantages compared to plastics crates -- especially considering that old corrugated boxes can often be sold to recycling companies, whereas the usage of plastic crates typically involves cleaning and returning costs.
China, India to be fastest growing national markets The fastest increases will occur in the world’s developing regions, although growth rates will moderate from the 2003-2008 period. The Asia/Pacific region, Eastern Europe and the Africa/ Mideast region will all outpace the global average. Some of the best gains are expected in China, which will surpass the US as the world’s largest corrugated box market by 2013; and India, which will benefit from strong growth in industrial output and consumer product markets, as well as greater investment in state-of-theart manufacturing equipment, resulting in improved product quality. Greater urbanization and industrialization, and expanding international trade will support advances in these regions’ generally underdeveloped packaging sectors. Rising consumer income levels and expanding middle-classes will also generate robust internal demand for packaged consumer goods like processed foods, beverages and personal care items, supporting increases in corrugated box consumption.
Recycled board to lead containerboard demand
The inauguration ceremony will be followed by plant visit and customer meet.
Global containerboard demand growth will trail box production as trends toward the use of higher-performance, lighter board continue. In addition, recycled board will continue to capture market share at the expense of virgin kraft liner and semichemical corrugated medium (fluting), accounting for over 70 percent of board by 2013. Advances for recycled board will be bolstered by consumer, industry and regulatory pressures for environmentally friendly products and practices, rising virgin board prices and rapid demand growth in Asia, which is heavily reliant on recycled liner and fluting.
Upal Roy, managing director at Flint Group India, said, “With a rapidly growing packaging industry in India, Flint Group is keen to cater to customers in this market. We already have an ISO 9001-2000 certified mother plant for packaging inks in Bangalore and blending units in Baroda, Noida and Savli, supported by depots at Pondicherry, Kolkata, Hyderabad and Navi Mumbai.”
Source: wwpe.net
The Vadodara plant meets European standards in terms of processes and safety. It consists of separate areas for the manufacturing of water-based, toluenebased and toluene-free solvent-based inks.
Flint Group to inaugurate new manufacturing plant in Vadodara Flint Group India, the ink manufacturing giant has shifted its manufacturing plant from Bengaluru to Vadodara. The new Vadodara plant will be inaugurated by Antoine Fady, CEO, Flint Group on 29 January 2013.
Roy added, “We are proud about the fact that we are in a position to support the market even further with our new plant in Savli.”
Next to the expansion of its packaging inks manufacturing operations in Poland and the acquisition of Torda, this is another important investment in a growth region for Flint Group’s Packaging and Narrow Web division this year demonstrating its strong commitment for continuous growth in the packaging segment. Source: Internet
Flint Ink’s new liquid ink manufacturing 42,000 sq/mtr plant in Savil near Vadodara, Gujarat
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Sole Agent
Mill Roll Stand
Glue Machine
High Speed Production
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
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
Single Facer
Securipax Packaging - Roorkee, Avon Containers - Faridabad, Santoshimatha Paper Products - Kakinada, Eswar Printpack - Rajahmundry, Kesho Packaging - Greater Noida, Heritage - Gurgaon
Successful Installations across India
Complete Corrugator Plant or individual machines to complement your own line can be supplied.
Production speed 80 - 250 mtrs/minute.
The Plant can produce 3 to 7 Ply Corrugated board in widths from 1400 to 2500 mm.
Corrugated Board Production Line
Forthcoming Events 8-11 April, 2013
12-15 June, 2013
30th August – 2nd September, 2013
BITEC, Bangkok, Thailand
Asia’s No. 1 Processing & Packaging Event
SinoCorrugated 2013 Setting New Heights Shanghai New International Expo Center, China SinoCorrugated 2013 will show the complete range of industry trends. With its focus on innovation, excellent service and complete industrial outlook, the show will serve as a high-value, efficient channel for exhibitors, visitors and buyers to engage one another and strike business deals. Featuring a total exhibition area of 61,700 sqm, 600+ exhibitors, more than 1,300 nos of corrugated equipment, over 1,000 consumables, several technical speeches and industrial seminars, the show is expected to receive 26,000 visitors and 50+ delegations from corrugated industry associations all over the world.
CCE International Munich Trade Fair Centre, Munich The launch of Europe’s only dedicated Exhibition for the Corrugated and Folding Carton Industry, CCE International, exceeded all expectations. A total of 2,040 visitors from 65 countries came to Munich to discover a comprehensive range of
With a proven track record ProPak Asia is the region’s trusted platform consistently delivering high quality and high quantity trade visitors from across Asia. ProPak Asia is supported by leading industry associations, whose special events including conferences, seminars and activity programmes add value and attract focused industry professionals to the show. 5-8 July, 2013
2013 HITEX International Exhibition Centre, Hyderabad, India www.packplussouth.in
machines, accessories and services for the production and conversion of corrugated and folding carton. With 110 exhibitors from 15 countries covering a net exhibition space of 3,300 m², the show made an impressive debut. A key feature of CCE International 2013 was the remarkably high international attendance, where both exhibitors and visitors were concerned. Almost 70% of the visitors and 80% of the exhibitors were from outside Germany.
Bombay Exhibition Centre (BEC), Goregaon (E), Mumbai IPEX India will deliver a new strong educational programme to attract and help printers and brand managers from the cross media landscape reach new business and profits. Our core target remains Print Service Providers (PSP’s) as they face great challenges on steering the right path for them to increase sales, profits and create greater efficiencies. Whilst brand managers, marketers, agency and publishing personnel are eager to understand how traditional and digital print can dramatically improve campaign ROI, how they can integrate marketing channels and how to find ways to provide value for customers. IPEX India will ensure your business evolves and embraces this rapidly changing market.
The general atmosphere at the show was very positive, and many participants stated that the results of this event have exceeded all their expectations. Most of this year’s exhibitors are already planning their participation at the next exhibition. CCE International 2015 is set to take place from 24 – 26 March 2015 at Messe München, Munich, Germany.
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