TRAINING REPORT

OF
FOUR / SIX WEEKS INDUSTRIAL TRAINING, UNDERTAKEN
AT

AMCO INDUSTRIES IN
PRODUCTION DEPARTMENT
ON

ENGINEERING TRAINER

SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE

OF
BACHELOR OF TECHNOLOGY
IN
DEPARTMENT OF MECHANICAL ENGINEERING

Submitted By:
Name: VANSH CHUGH

Under the Guidance of:

Name: SUNIL AGGARWAL

Programme: B.TECH (ME)

DIRECCTOR

Designation: EXECUTIVE

University Roll No: 130020201088

Department: PRODUCTION

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ACKNOWLEDGEMENT

The internship opportunity I had with AMCO INDUSTRIES was a great

chance for learning and professional development. Therefore, I consider
myself as a very lucky individual as I was provided with an opportunity to
be a part of it.
Bearing in mind previous I am using this opportunity to express my deepest
gratitude and special thanks to Mr. Sunil Aggarwal, Executive Director, who
in spite of being extraordinarily busy with her/his duties, took time out to
hear, guide and keep me on the correct path and allowing me to carry out
my project at their esteemed organization and extending during the training.
It is my radiant sentiment to place on record my best regards, deepest sense
of gratitude to Mr. Tribhuwan Upadhaya, Production Incharge for his
careful and precious guidance which were extremely valuable for my study
both theoretically and practically.
I perceive as this opportunity as a big milestone in my career development.
I will strive to use gained skills and knowledge in the best possible way, and
I will continue to work on their improvement, in order to attain desired
career objectives.

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PREFACE

This project report is based on the project we carried out at AMCO

INDUSTRIES, Production Department. My project was to set up an
automatic corrugation plant. The plant produces corrugated sheets from 3
ply to 5 ply. The plant reduces the cost of production, the manufacturing
time and increases the efficiency and effectiveness of production.
The report also contains detail about the various machines which help in the
manufacturing of corrugated boxes. There are 9 basic machines which are
involved in the process. The report contains a brief description about each
of the machine.

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TABLE OF CONTENTS

COMPANY PROFILE
INTRODUCTION TO ASSIGNED JOB

MODULAR DISCRIPTION OF THE JOB

ANALYSIS OF INDIVIDUAL MODULE

CORRUGATION MACHINE
HAND BOARD CUTTER
POWER CUTTER MACHINE
PASTING MACHINE
SLOTTER MACHINE
ROTARY MACHINE
DIE PUNCHING MACHINE
STITCHING MACHINE
BOX DRYER MACHINE
RAW MATERIALS USED
PROJECT UNDERTAKEN
SETTING UP AN AUTOMATIC CORRUGATION PLANT
INDUSTRY APPLICATION
CONCLUSION

REFERENCE

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1.COMPANY PROFILE
AMCO INDUSTRIES
PRODUCTION DEPARTMENT
ABOUT THE INDUSTRY:
AMCO
Industries,
Corrugated
Box
Making
Unit
was
established on 2nd Feb 1993. It was the first unit to be set up in
Sriganganagar District and within the radius of 250 km. For the past 22
years, AMCO Industries has been a pioneer in corrugated Boxes.
FOCUS OF THE INDUSTRY:
The main focus of the plant has been on packaging of oil producing units and
fruits. The plant aimed to replace the wooden Boxes especially in packaging
of Kinnows with Corrugated Boxes. In its Eco Friendly endeavour, they
succeeded in saving1200 tonnes of wood. Recyclable Boxes were used to pack
fruits and the demand is increasing every year. For taking this initiative
AMCO Industries was awarded at the District level for its efforts at
Independence
Day.
The company is pioneer and most experienced in their area. They cater to
multiple requirement of Boxes . The plant has Ultra Modern Machines such
as Die Punching Machines, Flexographic Printing Machines, Box Drying
Machine which reduces moisture as per requirement etc. They can make
small Boxes as well as Big Boxes up to 45x65 inches easily and the size can
be extended as per demand. They also make multicolor boxes.
The industry is headed by Mr. Sunil Aggarwal and his wife Mrs. Anju
Aggarwal. The company is achieving new heights with the help of their
dedicated staff and skilled labour.
The company has various clients from small manufacturers to MNC. EOU
units, oil companies and Fruit Suppliers are their valuable clients.

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1. INTRODUCTION TO ASSIGNED JOB

My job at the plant was to learn about the functioning of the various
machines used by the plant for the production of corrugated boxes. There
are nine basic machines used in the process. The machines are Corrugation
machine, Power cutter, Pasting machine, Slotter machine, Die punching
machine, stitching machine, Rotary machine, Hand cutter machine and Box
dryer machine.
They also gave a brief about the raw materials like the type of paper, gums,
stitching wire used.

2. MODULAR DISCRIPTION OF ASSIGNED JOB

My job at the plant can be divided into ten modules. Each module contains
detail about the machine and raw material used in the production of
corrugated boxes. The machines used are:a. Corrugation Machine:- Through this machine, corrugation of paper is
done.
b. Power Cutter:- The corrugated sheets are cut according to the given
specifications by this machine.
c. Pasting Machine:- This machine pastes the corrugated sheets and
plain paper together.
d. Slotter Machine:- This machine makes slots in the sheet.
e. Die Punching Machine:- The sheets are cut according to the design of
the die. The design varies from customer to customer.
f. Stitching Machine:- The machine stitches ends of the sheet to make a
box.
g. Rotary Machine:- Rotary machine is used for creasing and cutting
simultaneously
h. Hand Board Cutter:- This machine is used to cut corrugated boards
into sheets of required size.
i. Box Dryer Machine:- This machine is used to dry the box after the box
is completely manufactured.
j. Raw Materials used

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3. ANALYSIS OF INDIVIDUAL MODULE

3.1 MODULE-1: CORRUGATION MACHINE
High speed Single Facer Paper Corrugating Machine is used to make
corrugated paper rolls. These rolls are minutely finished and
mounted on spherical Roller Bearings, to give perfect impression on
Board. With self loading twin shaft reel stand, it has more production
capacity and efficiency than vertical type.

3.2 MODULE-2: HAND BOARD CUTTER

Hand Board Cutter is manually operated and is used for cutting of paper
or corrugated board in to sheets of required size. The machines is with
front and back guides.

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3.3 MODULE-3: POWER CUTTER

High Speed reels sheet cutter also called power cutter is used to cut paper
as well as 2 ply corrugated board. This machine can be operated in
alignment of corrugated machine instead of rewind & making rolls on
single facer.

3.4 MODULE-4: PASTING MACHINE

Sheet Pasting Machine is useful for gluing the fluted side of the board and
for pasting board to paper as well as to board for making 3-5-7 ply board.
The Machine is adjustable by rotating handle provided on one side of
machine.

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3.5 MODULE-5: SLOTTER MACHINE

This machine is used to make slots on corrugated sheets so that the sheet
can be folded and box can be formed. The machine can be adjusted as per
the dimensions of the box.

3.6 Module-6: ROTARY MACHINE

Rotary machine is useful for creasing and cutting simultaneously. The
machine is with two pairs of shafts. The front pair is with cutting dies and
rear pair is with creasing die. The lower shaft of each pair can be raised
or lowered by revolving side wheel. For easy feeding two guides are
provided.

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3.7 MODULE-7: DIE PUNCHING MACHINE

This machine is widely used for creasing and punching of cardboard
cartons as well as corrugated boxes. This easy to operate machine is
robustly constructed and can withstand heavy strains in continuous
operation.
Features: Impression Adjustment through two eccentric bushes
Electro Magnetic Clutch & Brake to eliminate possibility of
time lag between driving & breaking
Dual Timing Device to give a variable period from half to ten
seconds
Two Safety Devices to stop the moving block immediately and
isolate the starting mechanism
Standard Accessories : One Impression Plate, Two Steel
Chases, Feed and delivery boards, Centralized lubrication
system and tools

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3.8 MODULE-8:STITCHING MACHINE

Box stitching machine is most suitable for cardboard and corrugated
boxes. They have an adjustable feed up to 5/16 and 350 stitches per
minute with a power back up of 1/2 H.P. electric motor.
This Machine is used for last and final operation in box making. Parts are
standardized and interchangeable. Machine is capable of continues
running at high speed. Design of the Machine is universal & world
famous. The machine has very easy in operation, servicing & repairing.

3.9 MODULE-9: BOX DRYER MACHINE

As the name suggests, this machine is used to dry the box after the box is
completely manufactured. In this machine, the boxes are passed through
a set of heaters which dries the wet boxes. The temperature of the heaters
and the speed of the moving belt can be adjusted as per requirement.

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3.10

MODULE-10:RAW MATERIALS USED

a. Papers used: Semi Kraft paper from 12 to 20 BF(bursting force) 12kg/square
inch.

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 Media paper: white duplex, 100-250 GSM(gram square metre)

Media paper above 250 GSM are used as per demand.

b. Stitching wire used: Round Stitching Wires:These Round Stitching Wires are extensively used in printing
and packaging industry. Clients may choose the variety with
or without plastic spools depending on their specific
requirement.
Features:
1. Superior strength
2. Perfect finishing
3. Unmatched durability

Carton Stitching Wires:Page | 13

These carton stitch wires, are used for the packaging of

corrugated cartons.
Features:
1. Longer Durability
2. Higher Tensile Strength

Box Stitching Wires:Box Stitching Wire is used in corrugated carton assembly.

Stitching
Wire
Features:
1. High quality
2. Resistant to stain
3. Superior fitting
4. Effective Price

for

Corrugated

Industry:-

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c. Glue used: Starch based powder adhesives : Starch based powder adhesive
refers to the adhesive derived from starch. It has gained a lot of
popularity due to the lack of toxicity, economical cost and the
strength that it offers.
Advantages of starch based adhesives:1. Starch based adhesive is very cost effective.
2. Starch based adhesive is prepared from maize, tapioca,
wheat, potato, cassava, etc.. These crops are available in
abundance. Also it is renewable in nature.
3. Starch based adhesive has little or no odor.
4. Starch based adhesive is biodegradable in nature.

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4. PROJECT UNDERTAKEN
My project was to set up an automatic corrugation plant. The plant produces
corrugated sheets from 3 ply to 5 ply.
LINE DIAGRAM OF 5 PLY AUTOMATIC CORRUGATED BOARD
MAKING PLANT

WORKING OF THE PLANT:FROM PAPER TO CORRUGATED BOARD

The papers used in the production of corrugated are specific grades called
Linerboard and Fluting Medium.
The adhesive which is applied to the tips of the flutes is starch usually
originating from products of natural origin the most common being maize
(corn).
The Corrugator Machine:A Corrugator is a set of machines in line, designed to bring together three,
five or seven sheets of paper to form single, double or triple wall board. This
operation is achieved in a continuous process.
The reels of paper are fed into the corrugator, the paper is conditioned with
heat and steam and fed between large corrugating rolls which give the paper
its fluted shape in the Single Facer. Starch is applied to the tips of the flutes
on one side and the inner liner is glued to the fluting. The corrugated fluting
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medium with one liner attached to it is called single face web and travels
along the machine towards Double Backer where the single face web meets
the outer liner and forms corrugated board. The corrugated board is then
cut and stacked.
The main parts of a corrugator are the splicer and reelstand. These are the
machines which feed the paper rolls into the corrugator and enable rolls to
be changed without interrupting the production of corrugated board.
The single facer:
This machine transforms the paper into a series of connected arches
called flutes. The corrugating rolls are large cylinders with a
corrugated profile. If the flute profile has to be changed, then the
corrugating rolls need to be changed.
The double backer:
It glues the outer liner to the fluting to obtain single, double or triple
wallboard. The single face web is pre heated, starch is applied to the
tips of the flutes. The outer liner is then bonded to the single face web
to form corrugated board. It is a complex operation that requires great
expertise in the pre-heating, moisture control and gluing processes.
The bridge:
This enables the Double Backer to run at different speeds from the
Single Facer especially when reel or order changes take place. This is
achieved by the single face web forming festoons that are controlled at
the Single Facer station.
The glue unit and double backer:
Here, the single face web is prepared for glueing to the outer liner. It
is roughly the same process as the single facer unit with some
variations of the pre-heating and gluing processes.
The hot plate section:
It is at this stage that the single face web is combined with the outer
liner. The heating section ensures that the bond is strong by gelling the
glue and removing moisture.
The rotary shear:
After the board emerges from the Double Backer it passes under a
rotary shear that cuts across the whole width of the web. This is used
to chop out damaged lengths of board or to effect a change over from
one grade of board to another.
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 The slitter / scorer:

This operation slits and scores the board in the machine direction, with
the scoring which determines the style of the finished box.
The cut-off knives:
These cut the board to the exact required lengths to obtain the
corrugated sheet used in the making of corrugated packaging.
The stacker:
Finally, corrugated sheets are automatically stacked. Then they are
moved directly to the conversion machine or sent to a converting plant.

5. INDUSTRIAL APPLICATION
The automatic corrugation plant has several advantages such as:

The plant will help in reducing the cost of production.

It will increase the production.
It will reduce the manufacturing time.
It will increase the efficiency and effectiveness.
Less labour would be required.

These advantages will increase the demand of such plants and such
products. The quality of the product will improve and also money and
time would be saved.
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6. CONCLUSION
In my six weeks of training, I got to learn about the various machines, their
purpose, the raw materials used and the procedure of production of
corrugated boxes. Knowledge about these things will help me to better
understand the production procedure.
In my project, I learnt the steps involved in setting up an automatic
corrugation plant. The plant produces corrugated sheets from 3 ply to 5 ply.
Corrugated sheet is made up of one or more layers of corrugated paper. The
future scope of such kind of plant is that it will reduce the cost of production,
will increase the efficiency and effectiveness, will reduce the production time
and also the number of workers required.

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7. REFERENCES
http://www.madehow.com/Volume-1/Corrugated-Cardboard.html
http://m.nationalwireimpex.com/stitching-wire.html#stitchingwire-for-corrugated-industry

http://manveerexports.com/index.php/bearing-mounted-obliquetype-corrugation-machine
http://m.paperpackagingmachinery.com/corrugated-board-boxmaking-machinery.html

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