Equipment for the production of paper boxes. Tricks of the production of cardboard containers

The production of cardboard containers is considered one of the most profitable businesses worldwide. Packaging from this material is the most demanded. More than 50% of all packaging containers are cardboard products. This is due to light weight, strength and low price. This type of packaging is effectively used for transportation and wrapping. How to organize the production of cardboard packaging?

Benefits and uses

Due to the high demand for corrugated cardboard packaging, many start-up entrepreneurs are interested in its production technology and possible costs.

Equipment for the production of cardboard boxes

Carton packages for entrepreneurs have their own advantages over other packaging:

This is an environmentally friendly material.
Convenient dimensions when folded, you can transfer a large volume.
Production equipment is easily reconfigured for the manufacture of containers of any size and shape.
Boxes have a long shelf life, subject to all standards, so multiple use is allowed.
If advertising is applied to the surface of the box, packaging production can generate additional income.

The range of applications for cardboard packaging is very wide. Due to its lightness and environmental friendliness, the container is used in Food Industry. Packed in cardboard household appliances, electronics, cabinet furniture. Cardboard packaging is actively used as a gift; souvenir sets are packed into it.

There are also very interesting ways to use cardboard packaging. For example, in Japan, houses for refugees were made from cardboard boxes. And in China, coffins are made of cardboard. They are purchased in advance, and they are stored at home.

Cardboard production technology

For the production of cardboard products, cellulose and waste paper are needed.

Before a material can be put into production, it must be prepared. For this, the dissolution of the material is carried out, cleaning from large particles.

Cardboard packaging is produced in the following types:

Corrugated cardboard - it is made of seven or more layers. It is used most often for the transportation of large loads.
Microcorrugated cardboard - consists of two layers, used for household and household goods, medicines.
For the packaging of products, cosmetics, thin, durable cardboard is used - hlomersatz. These are expensive products.
Binding cardboard is produced for book binding, gift wrapping.
Designer look - used for making business cards, perfume packaging.

Any of the types should protect the goods from external damage. It is important that the size of the product inside the container matches the size of the package. Packing boxes protect the cargo during transportation, preserve its properties.

Production of cardboard packaging

Production requirements

Particular attention in the production of cardboard packaging should be given to the choice of premises. It must meet the following requirements:

The temperature and humidity of the air must be clearly controlled. Humidity should not exceed 80%.
Temperatures - at least 18 degrees in production and at least 5 in the warehouse.
All rules must be followed fire safety and properly ventilated.
The room must be safe from groundwater.

At the very beginning of production, the paper roll is placed in the room where it is conditioned. Then the roll is installed on the rolling machine. The paper goes through the machine to the cylinders, where it is heated and moistened. This process is necessary in order for the adhesive to better penetrate the structure of the material, and to ensure reliable adhesion.

The production of corrugated corton takes place on a specialized press, the temperature of 180 degrees is kept on it. Processing takes place in such a way that waves are formed on the surface of the sheet.

Then the paper is placed in the apparatus that applies glue.

Gluing machine for cardboard

The amount of the adhesive layer is controlled by a special dispenser. Corrugated cardboard is connected to a sheet of flat cardboard, the connection is made using a pressure roller. The result is a corrugated cardboard of two layers. If more layers are needed, a new layer of glue and a new layer of cardboard are applied.

Subtleties

At the final stage, the resulting sheet is transferred to the dryer. Here it is tightly glued and dried. The process of removing moisture is carried out with the help of steam. After that, the products are placed on the cooling machine. The cooling time depends on which characteristic the product must meet.

Finished sheets are transported to the cutting machine. With the help of circular knives, cardboard is cut into the right dimensions. On the same apparatus, the fold lines are determined, along them the boxes are easily assembled into three-dimensional forms.

Equipment for the production of

The main costly stage is the purchase of equipment for the production of packaging. It can be both Russian and imported.

Popular manufacturers are the Young Korean company YoungShinMachinery, the Chinese organization TRANSPACK.

TP-702NAD TRANSPAK Carton Making Machine

The equipment should consist of the following parts:

table for filing sheets;
printed sections;
cutting section;
sheet stacker that works automatically;
gluing machine;
drying compartment;
scoring machine;
waste paper press;
packing table;
Measuring instruments.

Modern machines can produce from 20 to 300 tons of finished products per day.

In addition to equipment, cellulose or waste paper will be needed as a raw material. They can be used simultaneously as part of each other.

Equipment for the production of packaging is fully automated. This allows you to hire a minimum number of workers. Personnel qualification plays important role in production efficiency.

The production of packaging board is profitable business. Cardboard products always enjoy in great demand both in the food industry and in any other field. Proper organization will help to get a good profit, and successfully develop.

In this article:

Packaging products made of cardboard and corrugated cardboard are today one of the most popular containers in the global, domestic market. The share of containers made from pulp and paper materials accounts for about 50% of the total volume of consumed packaging. This is due to the fact that cardboard and corrugated cardboard are light in weight, characterized by high strength and low price. Therefore, paper packaging is used not only as a shipping container, but also as an individual wrapper.

Due to the constant increase in demand for paper packaging, many entrepreneurs are interested in how to organize the industrial production of paper packaging from corrugated cardboard and cardboard? In order to answer this question, it is necessary to familiarize yourself with the technology of manufacturing corrugated cardboard and cardboard, analyze the production of cardboard packaging and organizational subtleties in opening an enterprise, and also draw up a detailed business plan.

Corrugated cardboard manufacturing technology

Before the production of corrugated cardboard, rolls of paper, cardboard intended for corrugation are placed in a room where the air temperature should be more than 15 °C. During the day, the process of their conditioning should be carried out.

After that, the rolls are fixed on the roll (unwinding machine) and then the prepared paper and cardboard are fed to the heating cylinders, intermediate rollers. On this equipment, the paper is heated and moistened. Thanks to this operation, the glue penetrates deeper into the paper and ensures reliable bonding with cardboard.

Further, the production of corrugated cardboard is carried out on a corrugating press. On this equipment, the paper passes between the corrugating rollers, the temperature of which is about 180 °C. As a result of processing, a wavy layer of a certain profile is formed.

After that, the corrugated paper is placed in a glue application machine, where an adhesive film is applied with the help of a glue shaft on one side. The amount of glue can be adjusted using a dosing shaft. Next, the corrugated layer is connected to a flat cardboard and processed by a pressure roller, and as a result, a two-layer corrugated cardboard is obtained. This operation can complete the production of corrugated board.

If a three-layer corrugated cardboard is required for the production of containers, then the two-layer corrugated cardboard is transported to a storage bridge, and then to a gluing machine. This equipment applies glue to the other side of the corrugated paper.

Finally, the corrugated cardboard is moved to the dryer, where it is glued and dried. The drying process can take place with the help of electricity and steam or drying plates. During this operation, moisture is removed from the corrugated board and the adhesive is cured.

After this operation, it is transported to the cooling part of the automated line. The cooling and drying process determines the characteristics of corrugated board.

Then sheets of corrugated cardboard are fed into the department longitudinal and transverse cutting, where it is cut and cut using circular knives. The cutting operation is very often combined with compaction. As a result of these operations, scoring lines are formed, thanks to which the sheet bending.

Finally, the corrugated board is cut into sheets of specified parameters. The sheets are further formed into corrugated cardboard packaging.

Equipment for the production of corrugated cardboard and packaging

A corrugated cardboard plant must have two lines:

Line for the production of corrugated cardboard;
Line for the production of corrugated cardboard packaging. A modern line for the production of corrugated cardboard should include a complex of high-performance automatic and semi-automatic equipment.

Lines for the production of corrugated board and packaging from TRANSPACK (China) are in great demand in the Russian market.

Therefore, it would be advisable for a novice entrepreneur to purchase the WJ-120–2200 D 1 line, maximum speed which is 120 m/min, and the maximum web width is 2200 mm.

To fully equip the plant, it is necessary to purchase a line for the production of corrugated cardboard packaging of the YKM-SB 3 series by TRANSPACK, which includes a set of machines for processing sheets and producing boxes of various dimensions. The maximum capacity of automatic box production lines can be no more than 6,000 packages per hour.

The TRANSPACK line includes the following list of main and auxiliary equipment:

Serving table;
3 pcs. printed sections;
cutting and scoring section;
Rotary die cutting section;
Automated sheet stacker;
Automated folder-gluing machine;
Scoring and cutting machine;
mini slotter;
Packing table;
waste paper press;
Dissolver for the production of glue;
Measuring instruments.

Taking into account the level of prices for equipment for the production of corrugated cardboard and packaging in 2013, capital investments for the purchase of lines will amount to at least 98 million rubles.

Cardboard production technology

The manufacture of cardboard is carried out as a result of a technological process that includes the following steps:

1. Raw material preparation includes a number of operations:

the dissolution of waste paper is carried out in the pulper.
cleaning of waste paper from large ingredients, which is carried out on a high-concentration vortex cleaner.
the additional dispensing of the cleaned mass is carried out in a pulsating mill.
fine cleaning.

Next, the mass enters the composite pool, where rosin glue, starch and alumina are added to its composition. In the end, the paper pulp is re-fine cleaned on knotters and vortex cleaners.

2.Cardboard dressing. The paper pulp goes to special machines, where the substance is subjected to dehydration and pressing, drying. As a result of these operations, the formation of a cardboard sheet is carried out. Finally, the recycled cardboard passes through the rolls of the machine calender, where under high pressure sheets are flattened.

The finished cardboard is wound on a tambour shaft and sent to a slitting machine. On this equipment, cardboard is cut into sheets. ending technological process cardboard production.

Equipment for the production of cardboard

The plant for the production of cardboard must have an automated line. Such a line should include a list of equipment for the preparation of waste paper and paper pulp:

Pulper;
Vortex cleaner, which allows you to eliminate heavy inclusions;
Turbo separator;
pulsation mill;
Disc mill;
vibrating sieve;
knotter;
Vortex cleaners to eliminate light inclusions;
Waste paper mixer.

The line for the production of cardboard should also include a specialized machine that forms the cardboard web, dewaters it and dries it. Modern machine for the production of cardboard can produce 20-300 tons of products per day, the maximum width of the web can be 6000 mm.

For the manufacture of cardboard, raw materials are needed:

cellulose,
waste paper
or their composition.

It is known that for the manufacture of 1 ton of cardboard it is necessary:

2 tons of steam;
1.1 tons of waste paper;
600-800 kW of electricity;
15-20 cu. m 2 of water.

Manufacturing technology of paper packaging from cardboard and corrugated board

The technology for manufacturing containers from cardboard and corrugated cardboard depends on the equipment available at the enterprise. Equipment for carton packaging is selected based on the planned production volumes, range and design of the box.

The production process for the manufacture of containers from cardboard and corrugated cardboard includes the following steps:

Sheet cutting. For cutting corrugated cardboard at enterprises, a cutting and scoring machine is used.
Printing. On the flexographic station, one-color or multi-color printing is applied.
Formation of blanks for boxes. Depending on the design of the boxes on this production stage different equipment can be used.
Gluing boxes. At this stage, the corrugated cardboard packaging enters the folder-gluer.

The machine for the production of boxes works in automatic mode.

Finishing production process cardboard products are formed into bundled bundles, which are placed on a pallet. For further convenience of transportation, the packs are tied into pallets. This operation completes the production of cardboard boxes.

Organizational subtleties in opening an enterprise

To organize an enterprise for the production of corrugated cardboard and corrugated packaging, it is recommended to register a business as an LLC on common system taxation.

OKVED codes:

21.21 - "Production of corrugated cardboard, paper and cardboard packaging";
21.11 - "Production of cellulose and wood pulp";
21.12 - "Production of paper and cardboard."

In the manufacture of corrugated cardboard and packaging, it is necessary to adhere to the standards of GOST 7376-89, GOST 7420-89, GOST 7691-81.

Business plan for organizing an enterprise for the production of corrugated cardboard and packaging from it

The planned enterprise should include two production sites:

For the production of corrugated cardboard;
For the production of containers.

For the production of corrugated cardboard, the company plans to order all the raw materials - paper and sheets of cardboard from OJSC "Marisky PPM". Delivery of raw materials will be carried out by railway and motor transport.

Requirements for production facilities

The production facilities in which the production of corrugated cardboard and boxes is carried out should have the following parameters:

For the production of corrugated cardboard, a room with an area of about 1400 m 2 is required;
It is necessary to allocate 1000 m 2 for the production of packaging. In the production room, ventilation should be designed in accordance with SNIP 2.04.05-91, fire safety system - SNIP 21-01-97. Temperature in industrial premises should be more than 18 ° C, and relative humidity - no more than 80%. Requirements for warehouses for finished products and raw materials

Warehouses for the storage of packaging and raw materials must comply with the following parameters:

Warehouse area for corrugated cardboard must be at least 500 m 2 ;
The warehouse area for raw materials should be 500 m 2 ;
Warehouses must be protected from groundwater and sources of moisture;
The air temperature in the premises should be more than +5 °C.

The need for staff by category:

Director;
Chief Accountant;
24 workers involved in the production process.

Total: 26 people.

The work of employees of the enterprise should be organized in 3 shifts. The duration of one shift is 8 hours, 5 day work week.

Cost of corrugated cardboard and packaging

To calculate the cost of 1000 m 2 of corrugated cardboard, we take into account the cost of raw materials for the manufacture of 1000 m 2 of finished products. The cost of raw materials for dressing 1000 m 2 of corrugated cardboard is: 3 rubles / m 2 * 1000 m 2 = 3000 rubles.

Total Сс=3000 rubles.

Electricity costs:

The production of 1000 m 2 of corrugated cardboard consumes 1500 kWh.

Total electricity costs (Se) will be: 1500 kW / h * 4 rubles. = 6000 rubles;

Steam costs for technological operations:

The cost of 1 Gcal of steam is C= 161.32 rubles;

The specific rate of steam consumption for the production of corrugated cardboard is 4 Gcal;

Total costs for steam (St) will be: 161.32 rubles / Gcal * 4 Gcal = 645.28 rubles.

Payroll costs for workers: 328,000 rubles per month, for a year - 3,936,000 rubles.

Co (expenses for the main and additional wages for workers for the manufacture of 1000 m 2 of corrugated cardboard) = 400 rubles.

Payroll taxes - 140 rubles.

Costs for the maintenance and operation of equipment (Ccm): 4000 rubles per year;

Calculation of the workshop cost of 1000 m 2 of corrugated cardboard: SSts \u003d Cs + Se + St + Co + SsmSSts \u003d 3000 rubles + 6000 rubles + 645.28 rubles + 400 rubles + 4000 rubles \u003d 14045.28 rubles

Workshop cost for the entire volume of corrugated cardboard manufactured in a year: SScg = 126406800 rubles.

Costs for the production of corrugated cardboard packaging

Let's assume that they make up 2.5% of the shop cost:

As a result of calculations, it was found that the annual cost of packaging from corrugated cardboard will be: 3110406 rubles, per unit. products (1000 m 2 of corrugated cardboard), the costs will amount to 352.3 rubles.

General factory expenses: 6220500 rubles per year, for 1 unit. products - 706.5 rubles.

The cost of renting premises: 1300525 rubles per year, for 1 unit. products - 152.1 rubles.

Total total cost will be: Sp (for 1000 m 2 of corrugated cardboard) = 15396.18 rubles, for the annual production cost will be - 862186.08 thousand rubles.

Revenue

The total volume of corrugated board for the month - 5821200 m 2;

The volume of corrugated packaging per month is 250,000 pcs. The average market cost of 1 m 2 of corrugated cardboard is 15 rubles.

The total proceeds from the sale of corrugated cardboard will be: 5821200 m 2 * 15 rubles / m 2 = 87318000 rubles. The company plans to sell part of the corrugated packaging (50%) at a price of 20 rubles per piece, and the rest - 25 rubles per piece.

The total proceeds from the sale of corrugated packaging will be: 125,000 pcs. * 20 rub. + 125000 pcs. * 25 rub. \u003d 25000000 + 31250000 \u003d 5625000 rubles.

Total revenue for the month: 92943 thousand rubles.

Revenue for the year will be 1115316 thousand rubles.

Net profit for the year will be: 1115316 thousand rubles - 862186.08 thousand rubles = 253129.92 thousand rubles, net profit per month- 21094160 rubles.

Capital investments for the purchase of equipment amount to 98 million rubles.

With this monthly income from production activities payback period will be 5 months. The calculations showed that the organization industrial production corrugated board and packaging – cost-effective and advantageous view business.

Investments: from 850 thousand rubles

Payback: from 3 months

Today, 80% of exported and imported goods are transported in cardboard boxes. It is lightweight, environmentally friendly and recyclable. Therefore, the cardboard box business is very profitable.

business concept

The bottom line is to open the production of cardboard boxes, which will be sold to various plants and factories. The advantage is that you do not need to sell your products individually, you need to find several large customers who will be sold all the goods. These can be confectionery factories, wine and vodka factories and any other enterprises in the food industry. Manufacturers of equipment and electronics also need cardboard boxes.

What is required for implementation?

The best thing this business will of course work in major cities where it is easy to find a potential client. But if in a small town there are enterprises that produce and sell own goods, then it will be more profitable for them to purchase cardboard boxes from you than to order in another city.

The main cost-intensive step in the implementation of a business idea is the arrangement of the premises and the purchase necessary equipment and raw materials.

The most difficult thing is to find a room that meets the following requirements:

average area 100 sq. m for machines and 50 sq. m for a warehouse;
air temperature in the room + 18 degrees, in the warehouse +5, humidity - 80%;
the room must be absolutely dry, protected from moisture.

The next step is to purchase equipment. The manufacturing process itself consists of the following steps:

sheet cutting;
printing on cardboard;
making box molds;
gluing containers.

This requires the following equipment:

cutting and scoring machine;
flexographic machine;
automatic press;
folder gluer.

In addition to all this, it is necessary to create conditions for the work of employees, allocate a corner for managers and accountants, or rent a separate office. Equip the premises with a bathroom, a video surveillance system and an alarm system.

Step by step start instructions

After financial plan all calculations have been drawn up and made, you can proceed to the implementation of a business project:

Registration. Obtaining all necessary permits for the production and sale of products.
Search and equipment of the premises, office and warehouse. It is ideal to combine all three rooms in one, or so that they are close to each other.
Hiring employees: an accountant, a security guard, at least three workers. Perhaps you will conduct all the documentation and financial calculations yourself. This reduces the need for one employee.
Purchase of equipment. At least 4 machines, tables for work, furniture for employees, plumbing, office equipment will be required. All equipment can be bought and used. In addition, you will have to spend money on surveillance cameras and alarms. You will also need a vehicle to deliver the goods.
Purchase of raw materials. Boxes are made from corrugated cardboard.
Advertising. Any marketing techniques can be used: advertising in the media, the Internet, announcements at bus stops, banners and booklets. Initially, you can order advertising booklets with detailed information about your business, product and prices, as well as personally provide them to all enterprises - potential customers.

Financial calculations

Start-up capital

So, initial investment into the cardboard box business:

25,000 - registration of an enterprise;
30,000 - rent of premises;
100,000 - salary to employees;
400,000 - purchase of equipment, machinery and raw materials;
20,000 - advertising;
20,000 - transportation costs;
50,000 - miscellaneous.

In general, to start and develop a business, you need to invest an average of 625-650 thousand rubles. The larger the scale of production, the higher the amount of investment.

Monthly expenses

Each month, the following costs are provided:

30,000 - rent of premises;
80,000 - salary to employees;
20,000 - purchase of corrugated cardboard - 1,000 sheets;
10,000 - advertising;
20,000 - transportation costs;
50,000 - utility and tax payments.

Every month you need to spend 230-250 thousand rubles.

How much can you earn?

One sheet of corrugated cardboard costs about 20 rubles. The production of one package requires 1/10 of a sheet of corrugated cardboard. A packing box will cost 20 rubles, that is, 10 packs are obtained from one sheet. In total, this is 200 rubles. On a day, 5 workers can make a minimum of 150 pieces each. The daily profit, respectively, is 15 thousand rubles, the monthly profit, taking into account days off, is 390 thousand rubles. After deducting all investments, the owner is left with 140 thousand rubles. With large scale production, profits will be significantly higher.

Payback periods

At good sales payback will come in three months.

Business risks and cons

The main problems associated with this case are the arrangement of suitable premises and the search for clients. In addition, domestic troubles may arise, as in any production - problems with transport, with the supplier of raw materials, workers, equipment breakdowns and much more. All this, of course, can be avoided with a well-thought-out and well-written business plan.

Conclusion

In general, the cardboard box business is a commercial business that is profitable and relevant. And this business will generate income as long as food, beverage or technology manufacturers have a need to transport their goods.

Containers made of corrugated cardboard continue to be very popular and not only in our country. If we consider the report of experts, then in Russia 78% of all freight traffic are carried out using corrugated cardboard packaging, which means that every year there is an increase in demand for products by at least 10%.

Such boxes are mainly created using corrugated cardboard. Such business can be engaged not only in large private companies, but also in medium and small businesses.

Required premises

First you need to choose the right premises for your business. It is also important to take into account that equipment for the manufacture of boxes should be freely located in it, and this is not less than 50 sq.m. territory. Thus, if you have your own large room, then this is a big plus. Otherwise, you will have to think about renting first.

Like the lease of any territory, its cost depends on many factors, ranging from the city to communications. For example, consider a small city with 200,000 inhabitants, and the location is envisaged on the outskirts. In this case, the approximate cost will be around $1 per sq.m. To rent a room of 100 square meters, you will need $ 1,000 per month, roughly speaking.

Working staff

After you have decided on the premises, you will need to think about hiring people, which should also be included in the business plan for the production of cardboard packaging. To do this, you will still need to think about whether you yourself can take part in the production process or only perform duties CEO. After all, you can initially combine both in order to somehow save money.

Bearing in mind that the production of boxes will be almost entirely automatic line, then at work you will need only one employee to begin with, who will collect such boxes and check them. For such work, special knowledge is not needed, everything can be learned very quickly. In order for all the work to be done with high quality, you can put a salary of $ 300 for the worker. This in small town will be more than enough.

Equipment, raw materials and advertising

For full production you will need Production Line, the cost of which can be $ 15,000 if we consider the used version. This is an almost fully automatic line, which can be operated by one person.

In order to be able to produce products, you will need raw materials in the form of corrugated cardboard sheets, from which boxes will then be stamped in disassembled form. You can easily find suppliers of such material, as there are plenty of them on the market. Do not rush to start working with the first one that comes across, take a closer look at the prices, the quality of the material and other nuances. Perhaps there are reviews of those people who have already worked with them. In general, you need to choose the most the best way.

To start production, it will be necessary to prepare at least $ 1,000 for the purchase of 2,000 sheets 1.2 meters long.

Income and expenses

One sheet of corrugated cardboard can cost half a dollar, and you can make products from it for $5 if you can find one. good customer. Thus, the income from one sheet of paper will be 4.5 dollars. If you invest $1,000 to buy 2,000 sheets, you can sell the product and earn $10,000. But it is better to count on 5000-6000 dollars of net income from such a number of sheets and taking into account all costs.

Now you just have to look for new customers and expand own production. And the equipment itself will be enough for you for a very long time, because the simplest one can produce about 100 pieces of products per hour. And here it is already easy to calculate how much you can earn approximately per day with a full load of production and work in three shifts.

As you can see, the cardboard box making business itself is not complicated at all. the main task is to find regular customers, which will be able to sell finished products, and this will bring you a lot of money.