Our Manufacturing Process
Take a virtual tour of our 10,000 sq. ft. manufacturing facility in Thane. From raw paper to finished corrugated boxes, every step is automated, quality-controlled, and optimized for efficiency.
From Raw Material to Finished Product
Our 7-step manufacturing process ensures consistent quality at every stage.
Paper & Raw Material Procurement
We source high-quality kraft paper and recycled liner from FSC-certified mills across India. Each paper lot is tested for GSM, burst factor, ring crush, and moisture content before acceptance. We maintain strategic relationships with leading paper mills to ensure consistent supply and competitive pricing.
Key Specifications:
- Kraft paper: 80-350 GSM
- Test liner: 100-200 GSM
- Fluting medium: 80-180 GSM
- Moisture content: <8%
Corrugation Process
Our high-speed corrugator machine transforms flat paper into fluted corrugated board. The fluting medium is heated, moistened, and passed through corrugating rolls to create the characteristic wave pattern. It is then bonded to flat liner boards using starch-based adhesive. Our corrugator operates at speeds up to 250 meters per minute.
Key Specifications:
- Corrugator speed: 250 m/min
- Board width: up to 2200mm
- Flute types: A, B, C, E, F
- Automatic tension control
Flexographic Printing
Our multi-color flexographic printing presses deliver high-quality graphics directly on corrugated surfaces. We use water-based, eco-friendly inks and precision anilox rollers for consistent ink transfer. For photo-quality requirements, we offer lithographic lamination with offset-printed paper overlays.
Key Specifications:
- Up to 6-color printing
- Max print area: 1600 x 1200mm
- 150 LPI resolution
- Pantone color matching
Die Cutting & Creasing
Custom die-cut shapes are created using CNC-machined steel rule dies. Our rotary and flatbed die cutters create precise cuts, creases, slots, and perforations with tight tolerances. Auto-fed die cutters ensure high-speed production with consistent quality across all pieces.
Key Specifications:
- Flatbed max: 1600 x 1200mm
- Rotary max: 2400mm width
- Tolerance: ±0.5mm
- Auto stripping & stacking
Folding & Gluing
Flat die-cut blanks are folded and glued into finished box shapes using automatic folder-gluers. Multiple glue patterns (straight line, crash lock, 4/6 corner) are supported. Speed and precision are maintained through servo-driven belt systems and camera-based quality inspection.
Key Specifications:
- Speed: up to 30,000 boxes/hr
- Crash-lock bottom capability
- Hot melt & cold glue options
- Camera QC inspection
Quality Testing & Inspection
Every production batch undergoes comprehensive quality testing in our in-house laboratory. We test for burst strength, edge crush test (ECT), box compression test (BCT), moisture content, and Cobb value. Statistical process control ensures consistent quality across all production runs.
Key Specifications:
- Burst Factor Test (BF)
- Edge Crush Test (ECT)
- Box Compression Test (BCT)
- Cobb water absorption test
Packaging & Dispatch
Finished boxes are bundled, palletized, and stretch-wrapped for safe transportation. Our dispatch team coordinates with logistics partners to ensure timely delivery across India. Real-time tracking is provided for all shipments.
Key Specifications:
- Automated bundling
- Pallet stretch wrapping
- Pan-India delivery network
- Real-time shipment tracking
Equipped With World-Class Machinery
High-Speed Fingerless Corrugator
VIRDI
250 m/min, 1575mm width
Flexo Printer Slotter
Multi-color inline
6-color, 1600mm width
Rotary Die Cutter
Servo-driven precision
2400mm, auto-feed
Auto Folder Gluer
High-speed folding
30,000 boxes/hour
Flatbed Die Cutter
Hydraulic precision
1600 x 1200mm
Litho Laminator
Sheet-to-sheet
1300mm width
Stitching Machine
Wire stitching
Heavy-duty capability
Testing Lab Equipment
In-house QC lab
BF, ECT, BCT, Cobb
Schedule a Factory Visit
See our manufacturing capabilities in person. We welcome plant visits from prospective clients and industry partners.
Book a Factory Tour