Corrugation & Packaging Production

Uncategorized

About Course

The Corrugation & Packaging Production course is a comprehensive, industry-oriented training program designed to develop skilled professionals for the fast-growing packaging sector. This course provides in-depth knowledge and hands-on experience in corrugated box manufacturing, duplex monocarton production, rigid box making, lamination, die-cutting, finishing, quality control, costing, and live factory production.

Students learn the complete packaging workflow—from raw material selection and paper science to corrugation line operation, flexo and offset printing integration, box conversion, finishing techniques, and final dispatch. Special emphasis is placed on industrial standards (FEFCO), quality testing (BF, ECT, Cobb), safety, maintenance, and production planning.

The program includes extensive live production training, real job handling, and a final project, ensuring students graduate as job-ready packaging technicians capable of working in corrugation plants, packaging factories, and box manufacturing units.

Understand packaging industry structure, standards, and workflows
Identify and select correct paper, kraft, duplex, SBS, and grey board materials
Measure and interpret GSM, BF, ECT, Cobb value, and moisture content
Operate corrugation plants for 2-ply, 3-ply, and 5-ply boards
Control starch preparation, temperature, and adhesive application
Perform sheet cutting, slitting, scoring, and flute inspection
Carry out flexo printing on corrugated sheets
Execute duplex-to-corrugated lamination and sheet pasting
Operate punching and die-cutting machines (manual & automatic)
Use folder–gluer and stitching machines for box formation
Manufacture monocartons, mailer boxes, pizza boxes, and e-commerce packaging
Create rigid boxes including magnetic, drawer, and premium gift boxes
Apply packaging decoration techniques such as lamination, foil, UV, embossing
Produce short-run and prototype packaging using digital die-less cutting
Perform quality control tests (BF, ECT, Cobb, compression, visual QC)
Plan production, calculate yield, and estimate packaging costs
Follow factory safety rules and basic machine maintenance
Handle real packaging jobs during live production training

Course Content

CHAPTER 1 INTRODUCTION TO PACKAGING INDUSTRY

1.1 Understanding the Purpose of Packaging
1.2 Global Packaging Industry Overview
1.3 Indian Packaging Industry
1.4 Types of Packaging: Primary, Secondary & Tertiary
1.5 Major Categories of Boxes
1.6 Packaging Workflow (Design → Dispatch)
1.7 Evolution of Packaging in India
1.8 Sectors that depend on Corrugated & Packaging
1.9 Role of Corrugated Packaging in Modern Supply Chains
1.10 Understanding Box Performance Parameters
1.11 Introduction to Corrugated Manufacturing Units
1.12 Understanding Box Styles (FEFCO Standards)
1.13 Introduction to Printing for Packaging
1.14 Hands-On Work for Week 1
1.15 Impact of Packaging on Branding
1.16 Environmental Impact and Sustainability
1.17 The Future of Packaging Careers
1.18 Summary of Chapter 1

CHAPTER 2 PAPER & BOARD SCIENCE

2.1 Introduction to Paper & Board in Packaging
2.2 GSM (Grams per Square Meter)
2.3 Bursting Factor (BF)
2.4 Edge Crush Test (ECT)
2.5 Moisture Content in Paper
2.6 Paper Types Used in Packaging
2.7 Flute Types in Corrugated Packaging
2.8 Role of Flute Geometry
2.9 Paper Defects in Packaging Industry
2.10 How to Select Paper for Different Boxes
2.11 Importance of Paper Testing in Packaging
2.12 GSM Measurement (Practical)
2.13 Identifying Flute Types (Practical)
2.14 Testing Kraft Paper (Practical)
2.15 Sustainability & Paper Recycling
2.16 Summary of Chapter 2

CHAPTER 3 CORRUGGATION FUNDAMENTALS

3.1 Introduction to Corrugation
3.2 Types of Corrugated Boards
3.3 The Corrugation Line – Key Machine Units
3.4 Understanding Kraft Paper in Corrugation
3.5 Understanding Fluting Medium
3.6 Adhesive / Starch Preparation
3.7 Temperature & Heat Control
3.8 Tension Control
3.9 The 2-Ply (Single Face) Making Process
3.10 The 3-Ply Manufacturing Process
3.11 The 5-Ply Manufacturing Process
3.12 Corrugation Defects & Their Causes
3.13 Practical: Starch Mixing
3.14 Practical: Observing 2-Ply Formation
3.15 Practical: Identifying Defects in Boards
3.16 Quality Parameters for Corrugated Boards
3.17 Safety in Corrugation Lines
3.18 Summary of Chapter 3

CHAPTER 4 BOX STRUCTURES & DIELINES

4.1 Introduction to Box Structures
4.2 Understanding FEFCO Standards
4.3 Most Common FEFCO Styles Used in India
4.4 Essential Structural Elements in a Dieline
4.5 Structure of Common Boxes
4.6 Principles of Creasing & Slotting
4.7 Understanding Die-Cutting Tools
4.8 How to Read a Dieline (Step-by-Step)
4.9 Layout Optimization for Box Making
4.10 Manual Box Mockup Preparation
4.11 Common Problems in Box Structure
4.12 Practical Work – Week 4
4.13 Summary of Chapter 4

CHAPTER 5 SINGLE-FACER & E-FLUTE PRODUCTION

5.1 Introduction to Single-Facer Operation
5.2 Function of a Single-Facer
5.3 Components of a Single-Facer Machine
5.4 Flute Formation Process – Step-by-Step
5.5 Importance of Temperature Control
5.6 Adhesive (Starch) for Single-Facer
5.7 Machine Speed & Synchronization
5.8 Paper Tension in Single-Facer
5.9 E-Flute Production
5.10 Defects in Single-Facer Operation
5.11 Practical – Operating Single-Facer (Under Supervision)
5.12 Safety Measures at Single-Facer
5.13 Quality Parameters for 2-Ply (Single-Face)
5.14 Summary of Chapter 5

CHAPTER 6 3-PLY & 5-PLY LINE OPERATION

6.1 Introduction to Multi-Ply Corrugation
6.2 Components of a 3-Ply & 5-Ply Corrugation Line
6.3 The 3-Ply Manufacturing Process – Step-by-Step
6.4 The 5-Ply Manufacturing Process – Step-by-Step
6.5 Understanding Ply Combination Strength
6.6 Critical Parameters in Multi-Ply Production
6.7 Common Defects in 3-Ply & 5-Ply Boards
6.8 Practical – Operating 3-Ply Line
6.9 Practical – Operating 5-Ply Line
6.10 Quality Check Parameters for Multi-Ply Sheets
6.11 Safety in Multi-Ply Corrugation Lines
6.12 Summary of Chapter 6

CHAPTER 7 SLITTING & SHEET CUTTING

7.1 Introduction to Slitting & Cutting
7.2 Machines Used in Slitting & Cutting
7.3 Purpose of Slitting
7.4 Thin Blade Technology
7.5 Understanding Scoring (Creasing)
7.6 Sheet Cutting (Length Cutting)
7.7 Key Parameters in Slitting & Cutting
7.8 Defects in Slitting & Cutting
7.9 Practical – Setting Up Slitter–Scorer
7.10 Practical – Maintaining Thin Blades
7.11 Practical – Fixing Real Defects
7.12 Safety Measures in Slitting & Cutting
7.13 Quality Check Standards for Slit Sheets
7.14 Summary of Chapter 7

CHAPTER 8 FLEXO PRINTING ON CORRUGATED SHEETS

Student Ratings & Reviews

No Review Yet

A course by

podmanipur@gmail.com

Printed and digital course textbook
Detailed week-wise notes and diagrams
Real packaging samples (corrugated, duplex, rigid boxes)
Dieline drawings and box structure references
QC formats (BF, ECT, Cobb, size inspection sheets)
Costing and estimation templates
Job card and production planning formats
Live production exposure and factory practice
Final project guidance and evaluation
Portfolio development support
Course completion certificate

Freshers interested in packaging and printing industries
Students completing Class 10 / 12
ITI / Polytechnic / Vocational students
Printing press workers wanting to upgrade skills
Corrugation plant helpers and operators
Box-making unit staff
Entrepreneurs planning to start a packaging business
Designers wanting to understand packaging production
Professionals seeking hands-on factory experience

About Course

What Will You Learn?

Course Content

CHAPTER 1 INTRODUCTION TO PACKAGING INDUSTRY

1.1 Understanding the Purpose of Packaging

1.2 Global Packaging Industry Overview

1.3 Indian Packaging Industry

1.4 Types of Packaging: Primary, Secondary & Tertiary

1.5 Major Categories of Boxes

1.6 Packaging Workflow (Design → Dispatch)

1.7 Evolution of Packaging in India

1.8 Sectors that depend on Corrugated & Packaging

1.9 Role of Corrugated Packaging in Modern Supply Chains

1.10 Understanding Box Performance Parameters

1.11 Introduction to Corrugated Manufacturing Units

1.12 Understanding Box Styles (FEFCO Standards)

1.13 Introduction to Printing for Packaging

1.14 Hands-On Work for Week 1

1.15 Impact of Packaging on Branding

1.16 Environmental Impact and Sustainability

1.17 The Future of Packaging Careers

1.18 Summary of Chapter 1

CHAPTER 2 PAPER & BOARD SCIENCE

2.1 Introduction to Paper & Board in Packaging

2.2 GSM (Grams per Square Meter)

2.3 Bursting Factor (BF)

2.4 Edge Crush Test (ECT)

2.5 Moisture Content in Paper

2.6 Paper Types Used in Packaging

2.7 Flute Types in Corrugated Packaging

2.8 Role of Flute Geometry

2.9 Paper Defects in Packaging Industry

2.10 How to Select Paper for Different Boxes

2.11 Importance of Paper Testing in Packaging

2.12 GSM Measurement (Practical)

2.13 Identifying Flute Types (Practical)

2.14 Testing Kraft Paper (Practical)

2.15 Sustainability & Paper Recycling

2.16 Summary of Chapter 2

CHAPTER 3 CORRUGGATION FUNDAMENTALS

3.1 Introduction to Corrugation

3.2 Types of Corrugated Boards

3.3 The Corrugation Line – Key Machine Units

3.4 Understanding Kraft Paper in Corrugation

3.5 Understanding Fluting Medium

3.6 Adhesive / Starch Preparation

3.7 Temperature & Heat Control

3.8 Tension Control

3.9 The 2-Ply (Single Face) Making Process

3.10 The 3-Ply Manufacturing Process

3.11 The 5-Ply Manufacturing Process

3.12 Corrugation Defects & Their Causes

3.13 Practical: Starch Mixing

3.14 Practical: Observing 2-Ply Formation

3.15 Practical: Identifying Defects in Boards

3.16 Quality Parameters for Corrugated Boards

3.17 Safety in Corrugation Lines

3.18 Summary of Chapter 3

CHAPTER 4 BOX STRUCTURES & DIELINES

4.1 Introduction to Box Structures

4.2 Understanding FEFCO Standards

4.3 Most Common FEFCO Styles Used in India

4.4 Essential Structural Elements in a Dieline

4.5 Structure of Common Boxes

4.6 Principles of Creasing & Slotting

4.7 Understanding Die-Cutting Tools

4.8 How to Read a Dieline (Step-by-Step)

4.9 Layout Optimization for Box Making

4.10 Manual Box Mockup Preparation

4.11 Common Problems in Box Structure

4.12 Practical Work – Week 4

4.13 Summary of Chapter 4

CHAPTER 5 SINGLE-FACER & E-FLUTE PRODUCTION

5.1 Introduction to Single-Facer Operation

5.2 Function of a Single-Facer

5.3 Components of a Single-Facer Machine

5.4 Flute Formation Process – Step-by-Step

5.5 Importance of Temperature Control

5.6 Adhesive (Starch) for Single-Facer

5.7 Machine Speed & Synchronization