1. Changing requirement of Kraft paper properties for Automatic box plant
Presented by
Ram Kumar Sunkara – Chairman – R & D Committee
Federation of Corrugated Box Manufacturers of India.
At IPPTA seminar – 10th and 11th Dec 2015

2. National Energy Map for India
Published in year 2006.
Published by “Office of Principal Scientific Adviser to the Government of India”
Technology Vision – 2030.
Based on their findings for Paper Industry.

3. Projected Demand for Corrugated Boxes
Kraft paper demand in Million tons
G D P growth rate
Year
6.7 %
8.0 %
10.0 %
2016
4.29
5.66
7.42
2021
5.96
8.27
11.86
It is estimated that consumption will be 4.5 MT for year 2015
The projected demand based on 2003 business environment
There is vast change in business environment in 2015
We can expect demand of around 8.5 MT by the year 2021

4. Mckinsey report
Packaging has an annual global turnover of about $550 billion, and India’s share is about $16.5 billion per annum.
There will be a ten-fold increase in India’s middle class population by 2025,
This will further trigger the consumption of packaging materials.
This will bring another growth spurt to packaging,
The report also notes that the country needs more packaging professionals.

5. Thomas Schneider
President of the World Packaging Organisation (WPO), says,
In coming years the Indian packaging industry will see substantial growth.
The increasing awareness regarding clean water, safe food, and pharmaceuticals will drive this growth.
The rise of the Indian middle class, which is expected to go from today’s 50 million to 583 million in 2025

6. Thomas Schneider
Also important is that the world’s multinational giants are taking rapid strides in India’s food, beverage, health and beauty, and pharmaceuticals sectors.
This will also drive growth in packaging.
These factors are forcing both packaging suppliers and end users to shift from bulk packaging to retail, unit-level, small-sized packaging.

7. Smithers Pira
Smithers Pira expects the global packaging industry to grow to $820 billion by 2016, and
The Indian packaging industry is growing at a rate of about 18 percent annually.
Packaging of essential products like food, beverage, milk, vegetable, food grains, and pharma are the key driving segments because of the huge domestic consumption.

8. Changes in the corrugated box industry
The corrugated box requirement will increase from 4.5 million tons to 8.5 million tons by year 2021.
There will be a need for additional capacity of 4 million tons of corrugated boxes.
This additional capacity will created by installation of more and more automatic plants for box manufacturing.

9. Changes in the corrugated box industry
Corrugation machines speed’s increasing at fast pace.
From 8 to 10 m/m two decades ago to current 250 m/m.
BF no longer the only performance criteria.
RCT came in about 5 years ago and is yet to be fully understood.
New performance standards being introduced in corrugated boxes.

11. Changes in the corrugated box industry
Flat crush test (FCT) of corrugated board which depends on Concora medium test (CMT) for fluting paper
Bending stiffness of corrugated board which depends on tensile stiffness and bulk of paper.
Heavy metals presence to be below 100 ppm. Customers insisting on certificates for the same.

12. Changes in the corrugated box industry
Requirement of different properties in Kraft paper for Liners and medium.
Corrugation industry was using same Kraft paper in liners as well as in fluting all these years.
However with newer demands on box performance standards, it has become necessary to use paper with different properties in liners and medium.

13. What is Liner and medium?
Double face Liner
Medium
Liner

14. Liner and Medium properties
For smooth running of corrugators, certain properties are very important.
These other than the usual ones we normally concentrate on like BF, RCT, and GSM.
Let us quick look at these properties.

15. Paper Quality Issues – Reel Finishing
Reel joints.
Moon cuts.
Peel offs.
Reel hardness.
Reel tension.
S. S. Consultants

16. Paper Quality Issues- Reel Finishing
Run 1
Run 2
Run 3
Boxes Prod. in Nos.
1600
2008
1840
Set up time in min. 15 22
Run time in Hrs
1h 15m
2h 35
2h 10m
Paper Qty used Kgs
4788
6349
4687
Mill: Top liner
Imp L
Mill: Medium 2 plies
R+R
K+K
Mill: Liners 2 plies
K+R
K+A
S. S. Consultants

17. Paper Quality Issues – Reel Finishing
Run 1
Run 2
Run 3
Board wt in Kgs
4622
6009
4302
Wastage in Kgs
166
340
385
Prod. Rate Kg/min
63.84
40.96
36.05
Wastage in %
3.46
5.35
8.22
Down time in min.
nil 36 45
Reasons
Paper defects
S. S. Consultants

18. Down time due to bad paper
Month
Aug 15
Sept 15
Oct 15
Total Down time (min)
3594
3963
3738
Down time due to paper defect (min.)
2269
2535
1964
No of times
388
333
346
% of total time
63.1%
63.9%
52.5%

19. Standardization of GSM and BF
If we are talking about optimizing corrugator speeds, then must also look at optimizing paper machine operations.
One of the biggest issue in optimizing paper machine is too many GSM’s and in optimizing pulp mill is too many BF’s
We suggest that there should be standardization of GSM and BF so that both can benefit.
We are suggesting some standard’s as starting point for further discussions between both.

20. Test Liner 1 Cobb: 30 to 35 Moisture: 6.5% to 7% G S M 125 150 175 200
225
250
300
Caliper
Microns
170
235
270
335
400
B. F 33 31 29 28
RCT (CD)
kN/m
1.3
1.6
1.8
2.1
2.4
2.7
3.3
Porosity
Sec 30 35 40
Ram Kumar

21. Test Liner 2 Cobb: 30 to 35 Moisture: 6.5% to 7% G S M 125 150 175 200
225
250
Caliper
Microns
210
245
280
315
350
B. F 28 26 24
RCT (CD)
kN/m
1.20
1.45
1.70
1.95
2.25
2.50
Porosity
Sec 30 35 40
Ram Kumar

22. Test Liner 3 Cobb: 30 to 35 Moisture: 6.5% to 7% G S M 100 125 150 175
200
225
Caliper
Microns
145
180
215
250
290
325
B. F 24 22 21
RCT (CD)
kN/m
0.85
1.10
1.35
1.50
1.70
1.90
Porosity
Sec 30 35 40
Ram Kumar

23. Test Liner 4 Cobb: 30 to 35 Moisture: 6.5% to 7% G S M 100 120 140 160
180
Caliper
Microns
150
210
240
270
B. F 20 18 16
RCT (CD)
kN/m
0.75
0.90
1.00
1.10
1.20
Porosity
Sec 30 35
Ram Kumar

24. Media Cobb: 50 to 70 Moisture: 9.0% to 10.0% G S M 105 115 125 140 160
Caliper
Microns
180
195
215
250
CMT-30
Newton’s
200
220
240
270
RCT (CD)
kN /m
0.75
0.90
1.00
1.10
1.20
Porosity
Sec 30 35
Ram Kumar

25. Changing Requirements
These environmental pressures are changing the requirements of raw materials.
In paper –
Switching back from white top to brown top
Source reduction in form of down gauging.
Lowering Liner and fluting GSM, yet maintain the quality parameters.
High ring crush liner
High CMT medium.
Ram Kumar Sunkara - S S Consultants

26. What is the box industry looking for?
Consistency of total moisture
Moisture profile
CD caliper
Odor and cleanliness
Transport Protection
Labeling to include linear meterage.
Providing test certificates.
Larger roll diameter.

27. Thank you – Have a nice day
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