PROJECT PROFILE ON

MARTISHA INDUSTRIES
(Manufacture of Corrugated Boxes)

UNIT PROPOSED AT

PLOT.No. 8E , PHASE – III, PARAWADA, VISAKHAPATNAM

 INTRODUCTION

. M/s. MARTISHA INDUSTRIES will be establish by the

Proprietorship namely Kum. JAKKALA ANANDA JYOTHI, D/o. JAKKALA

ELISHA aged about 42 Years, residing at C/o : TF7, B Block, Sony Grand

Apartments, Ramnagar, Opp : BHEL Township, Visakhapatnam – 530012

The Registered Office is situated at C/o : TF7, B Block, Sony Grand

Apartments, Ramnagar, Opp : BHEL Township, Visakhapatnam – 530012

with the main object is Manufacture of Corrugated Boxes.

The functioning of the firm will look after by promoter have vast

experience in the field. They having more than of in this line of industry and

having very good public relations, especially with business community in and

Andhra Pradesh State.

 PROJECT AT GLANCE

01. Name of the Unit : M/s. MARTISHA INDUSTRIES

02. Name of the Promoter : Kum. Jakkala Ananda Jyothi

D/o. Elisha Jakkala

03. Address for communication : C/o : TF7, B Block,

Sony Grand Apartments,

Ramnagar, Opp : BHEL Township,

Visakhapatnam – 530012

04. Unit Proposed Location : Phase-III, Parawada,

Visakhapatnam

05. Constitution : Proprietorship

06. Sector : Small Scale

07. Line of Activity : Manufacture of Corrugated boxes

08. Project Cost : 85 Lakhs

09. Land Cost : 36 Lakhs

10. Buildings & Plant Construction : 15 Lakhs

11. Working Capital Margin : 30 Lakhs

12. Loan Funds from Banks : 50 Lakhs

13. Promoter Contribution : 30 Lakhs

14. Employment : 30 Persons

 INTRODUCTION

Corrugated is easy to recognize. Corrugated is made of paper and has

an arched layer, called "fluting," between smooth sheets, called "liner." This

arched layer provides corrugated with a very high strength-to-weight ratio.

The corrugated most commonly used to make boxes has one layer of

fluting between two smooth sheets. But there are many types of corrugated

available, each with different flute sizes and thicknesses.

Corrugated Paper boxes are extensively used in the packaging of

industrial as well as consumer goods. In some of products like crockery,

electronic items, automobile components, glass and cigarettes,

pharmaceuticals, soaps & cosmetics, biscuits, hosiery, toys, rubber & rubber

products, refrigerator, cooler & fans, proper type of packaging becomes very

important.

PRODUCTS AND ITS APPLICATION

Corrugated is an extremely durable, versatile, economical and

lightweight material used for custom-manufactured shipping containers,

packaging and point-of-purchase displays, in addition to numerous non-

traditional applications ranging from pallets to children's toys to furniture

 Corrugated Paper boxes are extensively used in the packaging of

industrial as well as consumer goods. In some of products like crockery,

electronic items, automobile components, glass and cigarettes,

pharmaceuticals, soaps & cosmetics, biscuits, hosiery, toys, rubber & rubber

products, refrigerator, cooler & fans, proper type of packaging becomes very

important.

MARKET POTENTIAL AND MARKETING ISSUES, IF ANY

With the steady rise in the industrial production, the demand for

corrugated paper boxes increasing every year. These boxes have got distinct

advantages such as light in weight, easy to fabricate as per required

specifications. The corrugated papers and boards may also find market in

the rural areas for packing of fruits, vegetables & eggs.

RAW MATERIAL REQUIREMENTS

 Craft Papers

 Glue

 Staples wire etc.

 Packaging Material

MANUFACTURING PROCESS

Calculation has been based on single corrugated sheet pasted with one

sheet of craft paper.

Two paper reels are run together on corrugated machine. One layer of

paper becomes corrugated after passing through the heated fluted rolls and

other is brought in contact with the former having been glued at the tips.

These two get pasted together and are wound in rolls.

 These will be procured on job work. By cutting this roll with board

cutters and gluing the corrugated side on pasting machine. A double face

board is produced by the 3rd ply of paper over it. This board is kept under a

sheet pressing machines for some time for setting of wet glued sheets.

Similarly board to board can be pasted to form thicker board i.e. 5 Ply, 7 Ply

and 9 Ply etc.

The size of a box is always given in terms of the inside dimensions,

with the longer dimension (length) of the opening given first followed by

width and depth. The most economical box for a given cubic contents has

the proportions of 2:1:2 (L:W:D). However, other proportions may also be

used. For manufacturing boxes of any particular dimensions, it is first

decided as to how the blanks for the boxes should be cut to minimise the

wastage.

Calculation of Weight of a Box:-

Weight of the box is equal to area of the sheet multiplied by

weight/cu.m. the sheet.

Area of sheet

(i) Length of the sheet required, 'a' = 2L + 2W + 2 inches.

(ii) Width of the sheet required 'b' = W + H

Where L = Length of the box

W = Width of the box

H = Height of the box

2" is the stitching margin.

Weight/sq.m. of sheets :

It will depend upon the number of plies & g.s.m. (grams/sq.m.) of

paper. For the corrugating media, on an average 45% extra material is

consumed compared with the plain one depending upon the size of flute. So,

weight per gsm of a 3 ply board would be as follows :- gsm of top liner

+(1.45 x gsm of media) + gsm bottom liner.

Printing:

There are different methods of printing the corrugated boxes. Some of

the small scale manufacturers are printing the boxes after fabrication, by the

technique of screen printing. However, printing can be done in a printer

slotter machine. In this machine, the blanks are printed using soft rubber

dies and the body score or vertical score and slots are introduced in the

board.
 Printing can also be performed on the paper sheet, before making

corrugated sheet/board. The layer of paper which will come outside of the

box, is printed on flexographic machine.

Corrugated Board:-

Corrugated fibre board consists of a flat layer of paper sheet

(liner) glued on one or both sides of a corrugated paper (medium). The

corrugated board is made by passing two layers of paper (usually kraft)

through corrugating machine. One layer of paper becomes corrugated after

being passed through the heated rolls and other is brought into contact with

it after the former having glued at tips.

 The corrugating 'medium' is generally made from a 0.009" thick (9

caliper) or 0.23 mm. The glue frequently used is starch or silicate of soda

adhesive. When only one liner is used, the product is known as "Single face"

or "two ply" board. This board is flexible in one direction. When the

corrugated medium is combined on both sides with flat sheets, it is known

as double faced or "3-ply board".

Advantages of Corrugated Fibre Board Boxes :-

Corrugated fibreboard boxes have replaced the wooden and tin

containers due to their several advantages for safe transportation of the

goods. These are discussed here under :

1) Light in weight (freight advantage)

2) Cellular structure with high compressive strength, resiliency & shock

resistance. Assured safety to delicate articles.

3) Can be stored conveniently in folded condition when not in use, thus

saving storage space.

4) Can be attractively printed, thus advertising advantage.

5) By lining, lamination or coating, they can be made water resistant and

resistant to other adverse conditions.

6) Easy to fabricate.

7) Contents packed in these boxes remain dust free.

8) Available throughout the year.

9) Expedites production due to one line conveyor packing.

10) Re-usable

11) No strapping necessary

12) Desired in export market

13) Eliminated dependency on natural wood.

Applications:-

Corrugated fibre board boxes are being used for the packing of

industrial as well as consumer goods. They are used for packing of

chemicals, drugs, tobacco, engineering goods, canned and bottled goods,

food, electrical appliances, confectionary, textiles, fruits, vegetables,

potteries, footwear, glassware and other fragile items, medical instruments,

photographic equipments and a number of other products.

The use-pattern of corrugated board containers is approximately as follows :-

Chemicals & Drugs

Tobacco

Engineering Goods

Canned & bottles goods

Light Engg.Products & Lamps

Electrical products

Confectionery

Textiles
Other (including fruits, potteries etc.)

Some of the products where corrugated fibreboard boxes find extensive

application are:-

1. Pharmaceuticals.

2. Glassware, crockery ware

3. Soaps & Cosmetics

4. Biscuits

5. Hosiery & ready-made garments

6. Electronic products

7. Breweries

8. Cigarettes

9. Footwears

10. Toys

11. Milk products & other food items

12. Tea & Coffee

13. Automobile components

14. Rubber & rubber products

15. Engineering items and consumer durable like refrigerators, TVs, Air

Coolers, fans etc.

16. Stationary items

17. Match boxes

18. Frozen fish

19. Apple, cherry, grapes etc.

20. Cashew nut industry

 It would not be an exaggeration if one states that practically every

product at some or the other stage, has to be packed in corrugated paper

board or box. Usually, at the manufacturer/wholesaler’s level the individual

units of a particular item are packed together in a carton/corrugated box for

the sake of convenience in handling/transporting.

The strength or weakness of corrugated paperboard depends upon the

member of ply, which vary from 2 ply to 9 ply. The higher the member of

the ply, the thicker and stronger will be the board. However, the strength

required will depend upon the purpose for which the corrugated board/box is

to be used. For example, to pack vials and tubes, a thinner quality or lesser

ply corrugated board would serve the purpose, while packing of a television

set or an air-conditioner will require a very sturdy corrugated box with

maximum ply. Similarly for electric lamps, a 2 ply flexible board is used.

The unit shall manufacture corrugated boxes of varying plys to suit various

needs.
 PROCESS FLOW CHART

Corrugated Sheets

Printing

Printed Paper Sheets

Cutting

Gluing (at tips) (Sheet Pasting Machine)

3-ply board

Cutting

Creasing

Slotting

Stitching

Finished Product
 INSTALLED CAPACITIES
S.No Description
Process Per Day
1 Raw Material Required 5 Kgs
Production 3.25 Kgs

Water Consumption
1.Utility water 2 KL
2.Drinking 0.2KL
2
Total 2.2 KL

Manpower Required
Particulars No of Staff
Skilled Operator 3
Semi Skilled Work Men 6
Administration Staff 3
3
Un Skilled Casual Labour 15
Security 3
Total 30

Power Consumption
Total Power consumed per hour 30 Kwh
Add: 10% Auxiliary Power Consumption 2 Kwh

Total Power Requirement per Hour 32 Kwh

Cost of power per Kwh 9.5

4
Cost of Power per Hour (in Rs.) 304
Production per Hour (in Kgs) 300

Cost of Power per Kg 1.01

BREAK-EVEN-EFFICIENCY ANALYSIS
Rs. Lakhs

1st 2nd 3rd 4th 5th

Year Year Year Year Year
Capacity Utilisation (%) 60 65 70 75 75
A. Sales 175.50 190.13 204.75 219.38 219.38
B. Variable Costs
Raw Materials, Consumables &
a. 131.63 142.59 153.56 164.53 175.50
Packing Materials
b. Power/Water 1.84 1.99 2.14 2.30 2.45
c. Wages 6.89 8.22 8.85 9.48 10.11
d. Intt. On Working Capital Loan 3.33 3.59 3.87 4.15 4.15
e. Sales Expenses 3.07 3.33 3.58 3.84 4.10
TOTAL 146.76 159.72 172.01 184.30 196.31
C. Fixed Costs
a. Salaries 4.31 4.74 5.21 5.74 6.31
b. Admn. Over head 1.76 1.90 2.05 2.19 2.19
c. Repairs & Maintenance 0.24 0.42 0.55 0.64 0.70
d. Insurance 0.49 0.64 0.74 0.80 0.84
e. Interest on term loan 4.20 3.68 2.63 1.58 0.52
f. Depreciation 6.39 5.53 4.78 4.14 3.59
TOTAL 28.74 16.91 15.96 15.09 14.30
D. Contribution 28.74 30.41 32.74 35.07 37.69
E. Break-even-efficiency (%) 60.51 55.59 48.75 43.03 37.95

Average Break – even efficienty 49.17

MACHINERY