The Box Manufacturing Process Explained

The humble cardboard box is one of the most used packaging materials. It is a core product in packaging manufacturing. It not only fills the shelves, but it can be seen all throughout the supply chain too. When looking at a cardboard box, typically printed and branded with inviting colours and wording, it is hard to imagine it started life as a tree. We discuss the box manufacturing process step by step.

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As consumers, we often forget to consider how items came to be, but we think the packaging should be celebrated. So, how does a tree finally become a box?

The steps of box manufacturing

1.     The tree

While we ideally look for recycled cardboard for box production, at one point, a cardboard box started life as a tree. Typically, the trees used for box manufacturing are softwood trees such as pine and fir tree. The reason they are chosen is that they have long fibres which can help to create a smooth finish for the cardboard as well as creating tension which increases the strength.

Many manufacturers will choose wood from sustainable and managed woodland; this means that any trees that are felled are replaced to help maintain the ecosystem of the forest. The paper and cardboard created will have a different colouring depending on the tree used. For example, silver birch trees will produce a dark colour, while a spruce will create a light brown colour.

2.     The pulp

From felling the tree, wood chips are made. These wood chips are then broken down into pulp. This can be done through grinding the wood against a stone or chemically cooking the wood chips. With this, you can add chemicals such as sodium sulphate to increase the strength of the pulp. For most cardboard, the pulp is left as the same colour. However, it can also be bleached to create a white appearance.

3.     Corrugation

Once the pulp has been dried, you can then start to create cardboard. For corrugated cardboard, it requires two pieces of paper or card called liners and a portion of fluted cardboard, which sits in between the liners. To fluting helps to give the cardboard further strength and a higher level of protection against damage.

Rolls of the paper made from the dried pulp are fed through a corrugated roller, which flutes or ruffles the paper. Depending on the quality of the box being made will depend on the level of fluting required. As increasing the fluting leads to higher use of material and therefore increased strength, this is used for high-quality boxes. For cheaper boxes, less fluting can be used which can help to create space-saving, a reduced amount of material used and can lower the carbon emissions.

The corrugation machine uses hot steam to create the flutes. At the same time glue is rolled down each side of the flute, so that is sticks to the liners. Once corrugated cardboard is formed, it is then trimmed to provide straight edges.

4.     Cutting

Now that you have complete corrugated cardboard, it is time to cut the card to size, depending on the box requirements. There is a comprehensive guide, and many of the machines are programmed to cut the cardboard to scale automatically depending on production demand. Once the basic outline has been cut, the card is then sent to a trimmer.

The trimmer is designed to deal with intricate aspects that the cutting machine cannot handle. A trimmer can add handles to boxes and cut flaps that are needed to construct the box. The trimmer also scores the cardboard, making it easier to fold when the box is ready for assembly.

5.     Assembly

Assembly will depend on the requirements of the box. The use of flaps and slots may be best for business who want to construct their boxes on demand. As well as these, boxes built with tape are often efficient to be constructed as and when they are required. Usually, for more robust boxes, glue and stitching are used to fold sections together and keep the box secure.

Specific innovative machinery can construct boxes for you on demand. For example, Ribble Right Size is an on-demand box making machine. It creates the perfect size box depending on your needs to reduce waste and ensure the best fit. The box is constructed for you which can significantly reduce packing production time.

After assembly, offcuts can be recycled to continue in the chain of box making. After the boxes have been branded, printed and utilised, they can be recycled and create a continuous cycle of recycled box manufacturing.

A small-scale box manufacturing business is ideal for entrepreneurs who have knowledge and experience in the commercial packaging systems and paper industries. Here is a step-by-step guide to starting a carton making business with costs, laws, and machines.

Whether you live in a metropolitan or suburban area, you can start this business. Every manufacturing business large and small needs a box. A beautiful and durable box is a must for getting the product into the hands of the end user.

1. Is a Corrugated Box Manufacturing Business Profitable?

Corrugated box manufacturing is a highly competitive industry. Profit margins are not large enough. However, with demand so high, there is always a chance for new entrants to find customers and make big bucks.

FMCG companies are major buyers of corrugated boxes. In addition, other industries such as apparel, apparel, pharmaceutical, dairy, automotive, and other product manufacturing industries are also large buyers of corrugated boxes.

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2. 8 Steps to Start a Corrugated Box Manufacturing Business

Corrugated boxes are used in a wide variety of applications and are a product that is always in high demand. More than 80% of industrial packaging is made of corrugated boxes because corrugated boxes have the advantages of effective buffering, lightweight, easy production, easy storage, easy disposal, no need for bundling, printing advertising, must be exported to the market, and recyclable.

Boxes come in different custom sizes and shapes, usually square and rectangular. The carton is made of corrugated cardboard, with 3-layer, 5-layer, 7-layer, and other specifications. The business involves buying corrugated cardboard from manufacturers or marketplaces and turning them into custom-made boxes according to the client's specific requirements.

Corrugated boxes are suitable for packaging in different fields such as beer, glassware, cigarettes, medicines, biscuits, milk and dairy products, soap, cosmetics, tea and coffee, food, clothing industry, chemical industry, agrochemical industry, leather, and so on.

Here are 8 steps to successfully start a box manufacturing business:

1) Learn the manufacturing process

Before entering the industry, it is important to master the skills in the product and the manufacturing process. Additionally, you should be familiar with the industry's ins and outs.

Even better if you already have an educational background in packaging. You can also go to some seminars on industrial packaging. You also need to know which specific boxes are best for a specific product. Therefore, you also need to guide your customers.

2) Corrugated box manufacturing business project plan

A detailed business plan is essential. A box manufacturing business requires modest capital to start. It is best to have customized project reports including machinery costs, raw material costs, working capital requirements, total investment, and financial analysis. At the same time, determine your box manufacturing business's mission statement and promotional or marketing strategy.

3) Corrugated box production and operation license

Each country has different licensing procedures. Check with the authorities and obtain the required licenses and permits.

In India, to start a box manufacturing business, you need to obtain a trade license from the local government. Also, you will need to obtain a factory license. Apply to the Pollution Control Authority for the establishment and operation consent.

4) Corrugated Box Manufacturing Machinery

To start a box manufacturing business, you will need to install machineries such as corrugators, printing presses, and cutting and gluing machines. Connect with multiple suppliers. Before buying a machine, check what the customers say about the machine company. Ensure the warranty period of the machine.

5) How much is the box machine

To produce boxes commercially, you need to buy semi-automatic or fully automatic machines. For larger operations, automated machines are always preferred. Prices start at $ for a good quality machine. You can request a quote for free on Alibaba Marketplace. If you need an automated box making machine for small businesses, you can request our currugaed box making machine, we will happy to provide you a quotation.

6) What is the profit margin?

The profit margin of traditional packaging boxes is around 5% of turnover. However, it can be increased by offering innovative designs and better quality boxes.

7) Box Raw Material

The main raw material of corrugated box manufacturing enterprises is kraft paper. You need to collect high quality kraft paper from your supplier. The quality of the kraft paper actually determines the quality of your box. Other raw materials needed are glue and needle and thread.

There are several different corrugated boxes that you can customize according to the customer's requirements. These are ordinary corrugated boxes, export quality corrugated boxes, cartons, cardboard boxes, printed cartons, silver plated corrugated boxes, etc.

8) Develop a promotion plan

First, potential buyers of corrugated boxes need to be identified in the industry. Contact them for your product catalog. Try to offer better business deals with a better look. Online registration on popular B2B portals. Make an online showcase for your paper packaging business.

Concentrate on designing part of the box to create an attractive image. Attend trade shows and business fairs and register with your local trade association.

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