Corrugation Process
This is the first and foremost step in the process of Box Making were two sheet of Liner paper with the same GSM (or) different GSM’s are merged together using 3 drums, which contains a Zigzag curving like bents which are widely termed a Flute. There is another type of Flute called E Flute. This type of Flute is mainly used in Footwear Industries.
Each Drum would holds a Heater, which needs 11 Kilo volts to get the drum heated up. To achieve the perfect temperature it would take from 30 to 45 minutes from the time of switching it ON. In a Corrugation Machine there is a Gum Tray were 1 Kg of chemical is mixed with 5 Litre’s of Pure Water.
After the completion of this process, the corrugated reel is ready for Cutting.
Cutting Process
The Corrugated Reel (CR) needs to be cut into Individual Boards, in this there are two major adjustments that needs to be configured in the machine based on the size of the box.
1. Blade Adjustments
a. Speed Adjustments such as Low Speed, High Speed
2. Measurement Configuration.
Once the above Adjustments & Configurations are completed the CR is loaded in the slot and once the machine is switched on the Blades cuts the CR according to the measurements.
Printing Process
Printing is a process which has been carried out with at most care, due to its complexity. Printing is a major piece of work, since it directly impacts our client’s reputation and their branding image. We perform single colour printing at our unit, using rubber dye’s in Kraft Paper. When it comes to Off Set printing Sri Sai Cartons outsources the work as a Job order to its Trusted Partners.
The Rubber Dye is completely customized for every client, based on their Logo, Colour & Branding Pattern.
Pasting Process
Once the Cutting process is completed and arranged one above the other, the entire set of individual boards are inserted in between two rollers which hovers the gum filled in the dedicated tray just below the roller. In the other end of the machine helpers hold the board and mergers a Top sheet according to the client’s requirement and arranges the boards one above the other for drying it. The drying time may vary depending on the external weather factors. This process also involves gum were 1 Kg of chemical is mixed with 5 Litre’s of Pure Water.
Scoring Process
In this phase the major two mandatory configurations that needs to be set before processing the boards are Dye Fitting & Blade Fitting. These adjustments vary based on the Length, Breadth & Height of the boxes.
Apart from the above mentioned adjustments the board level i.e. based on 3 ply , 5 ply & 7 ply adjustment needs to be set. The major task which is completed by Scoring Machine apart from edge cutting is the Setting up of Flaps (Fold) for the boxes which do not require stitching.
Slotting Process
Slotting is a the sixth process which is in line with the box completion stage, here the blade adjustment needs to be set according to the Length & Breadth.
In terms of the settings the operator should ensure that enough support is ensured for the Closing Flaps.
Punching Process
In this process, the boards need to have a cut, which will define the carton box’s perfect shape as per the client’s requirement more over this process is carried out using a dye. A dye is basically made up of a sharpen metal, fixed on a wooden cardboard and the vertical mounted metal is supported by rubber.
An Operator places the carton board which needs a cut on the bed and the bed moves against the dye in a To and Fro motion. The board gets a cut and the desired shaped gets delivered eliminating the unwanted carton pieces as waste.
Stitching Process
This is a process which is mandatory for the Non Locking Type Boxes more over its essential when the weight carried by the box exceeds 3 Kg’s. There is another scenario were stitching is mandatory i.e. if the boxes are arranged one above the other, which makes the bottom most box to bulge.
The adjustments are made, based on the ply of the boxes and steel coils are used for stitching, which are broadly classified as “Ordinary” & “Rust Proof” Coil.
Waste Management
In today’s environmental condition waste management is one the key process that needs a careful handling. We, at Sri Sai Cartons separate the waste into two main categories Printed waste and Non Printed waste. Post separation it has been dispatched on a daily basis to the Industries that turns the waste cartons back as Kraft Paper reels which will serve the purpose of an another Corrugated box Manufacturing Industry.