Step-by-Step Carton Box Manufacturing Process
1. Kraft Paper (Raw Material)
The main raw material used for carton box manufacturing is Kraft Paper. This paper comes in reel (roll) form and different GSM (strength) such as 120 GSM, 150 GSM, 180 GSM, etc.
Purpose:
- Used to make liner and flute paper
- Determines box strength (3 Ply, 5 Ply, 7 Ply)
2. Corrugation Machine (Paper to Board Conversion)
Machines Used:
- Reel Stand
- Single Facer Machine
- Sheet Cutter
- Sheet Pasting Machine
- Sheet Press Machine
Process:
- Kraft paper roll is loaded into Reel Stand
- Paper passes through Single Facer where flute (corrugation wave) is formed
- Liner paper and flute paper are pasted together
- Sheets are cut to required size
- Sheets are pressed and dried
Output:
Corrugated Board Sheets (2 Ply / 3 Ply / 5 Ply Board)
3. Sheet Cutting & Creasing
Machine:
- Creasing & Cutting Machine
Purpose:
- Cut the board into exact box size
- Create creasing (folding lines) for box bending
Output:
Cut and creased box sheet ready for slotting.
4. Printing Machine
Machine:
- Flexo Printing Machine
Purpose:
- Print company name
- Logo
- Product details
- Handling instructions
- Branding
Printing Type:
Flexographic Printing (Rubber Stereo Printing)
5. Slotting Machine
Machine:
- Slotting Machine
Purpose:
- Cut slots for box flaps
- Shape the box structure
- Make top and bottom flaps
6. Die Cutting Machine
Machines:
- Rotary Die Cutter
- Platen Die Cutter
Purpose:
- Used for special shape boxes
- Used for handle die cut
- Used for partition die cut
- Used for pizza box, shoe box, etc.
7. Folder Gluer Machine
Machine:
- Folder Gluer Machine
Purpose:
- Fold the carton sheet into box shape
- Apply glue and close the joint
Alternative:
Instead of gluing, stitching can be done.
8. Stitching Machine
Machines:
- Semi Automatic Stitching Machine
- Single/Double Head Stitcher
- Manual Stitching Machine
Purpose:
- Join the carton using metal pins
- Used for heavy duty cartons
9. Bundle Packing Machine
Machines:
- Strapping Machine
- Bundle Press Machine
Purpose:
- Bundle the finished cartons
- Prepare for dispatch
Summary – Complete Process Flow
Kraft Paper → Corrugation → Sheet Cutting → Creasing → Printing → Slotting → Die Cutting → Folding → Gluing/Stitching → Bundling → Finished Carton Box
Investment for Carton Box Factory (Approx)
| Factory Type | Investment |
|---|---|
| Small Scale | ₹3 – ₹6 Lakhs |
| Medium Scale | ₹15 – ₹40 Lakhs |
| Fully Automatic Plant | ₹1 Crore + |
