Industrial Report

Dissertation submitted to the

Post Graduate Diploma in Packaging
By
Sandhya.P
Under the guidance of
Mr. Madan Manipati
Dr. Gaurav Madhu
Indian Institute of Packaging

Hyderabad
Telangana

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 CANDIDATES DECLARATION

I, …………………………………, hereby declare that the Industrial report is an authentic record

of my own work as requirement of partial fulfillment of the degree during the period of 2020

september to 2021 June for the award of Post Graduate Diploma in Packaging in Indian Institute

of Packaging. Under the Guidance of Mr. Madan Manipati.

Sandhya.P.

Date: 25-11-2019
Place: Hyderabad.

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 ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to my teacher Mr. Madan Manipati
& Dr. Gaurav Madhu for their guidance, as well as Indian institute of packaging for giving me
this opportunity for guiding us through these visits, which helped me to learn and gain
knowledge. I am really thankful to them

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Contents

1. Navodaya Packaging
2. Bharadwaj CFB Pvt. Ltd
3. Agiglaspac Pvt. Ltd
4. Wings Paper Mills Ltd.

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 NAVODAYA PACKING INDUSTRIES

Navodaya Packing Industries, founded by Mr. Sivarama Krishna, CEO & MD, started its
operations in the year 2009. It is an ISO 9001:2015 certified company that manufactures and
supplies Fibre Drums and HDPE Drums. It is also a registered member of IIP (Indian Institute of
Packaging), India.

Mr. Sivarama Krishna, CEO & MD, ventured into this business in the year 2009 and started its
operations with manufacturing of Fibre Drums. From the year 2013, he ventured into HDPE
drums manufacturing too. Prior to this, he was into Bulk-drug industries from 1991-2001 and
later into chemical trading business from 2001-2009.

Navodaya Packing Industries established itself as a trustworthy organization, engaged in

manufacturing and supplying of HDPE Drums, Fibre Drums & Composite Containers. All our
products are developed under the strict supervision by quality experts as per industry set quality
standards. Moreover, our offered range is appreciated for their robust construction, compact
designs and compatibility.

Composite containers :

Where the composite containers consist of 4 parts:

1. Kraft paper
2. Poly vinyl paper
3. Hard board
4. Cold roll steel (steel ring)

Manufacturing process:

The kraft web roll is bought from another manufacturing unit where these are converted into
composite containers, where the web roll is cut into 10 parts equally with a particular
diameter .and then they are separated into different layers .

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 The 1st layer will be of poly vinyl paper which forms the outer most
layer of the container. Then the 2 nd layer consists of fevicol which helps in binding the first two
layers. Then the 3rd, 4th, 5th, layers are being binded together with a sodium silicate which acts as
a liquid gum. Then at last all the layers are binded together and are placed next to other and form
a cylinder shape.

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 Then they are sent for fixing the steel rings at the ends of the container but they are not
completely sealed. Where the steel rings thickness is of 0.5mm to this the electro spot wielding is
done and then the zinc coating is done in order to prevent it from rusting. This process is also
called as galvanizing.

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 After the ring is bent from two sides

The rings are 1st dipped in HCL solution as a cleaning process where it removes all the dust .

Then they are again washed with water

Then the rings are dipped in a tank which consist of zinc bar and a colour (gold and silver)

Allow it to stand for 10-15 mins in the same solution

Then these are dipped in water solution and washed thoroughly for twice

Desired color rings are obtained with coating

Hard boards this are generally used for every composite container they are placed at the ends of
the container. The hard board consists of both smooth side and rough side. Where the rough side
is sticked with paper of 150 gsm and sealed with plaster at corners.

Each board consists of thickness of around 6.5 -7mm.

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HDPE DRUMS:

These are the drums which are made up of HDPE plastic granules. it is also called as barrels .
Which different sizes are available?

These are 100% food grade material where there wills no moisture content taken into
consideration. The cost is around 100 rupees per kg.

To this the pigment colors are added in order to get different colors to the outer most layers.

First the HDPE granules are brought from another manufacturing unit where they are melted to
a high temperature and a viscous state material is formed which is rolled to a cylinder roll to
which the blow molding process is done.

Blow molding is a manufacturing process that is used to create hollow plastic parts by inflating a
heated plastic tube until it fills a mold and forms the desired shape. The raw material in this
process is a thermoplastic in the form of small pellets or granules, which is first melted and
formed into a hollow tube, called the parison. There are various ways of forming the parison, as
explained below. The parison is then clamped between two mold halves and inflated by
pressurized air until it conforms to the inner shape of the mold cavity. Typical pressures are 25 to
150 psi, far less than for injection molding. Lastly, after the part has cooled, the mold halves are
separated and the part is ejected.

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Parts made from blow molding are plastic, hollow, and thin-walled, such as bottles and
containers that are available in a variety of shapes and sizes.

Injection blow molding: The molten plastic is injection moulded around a core inside a parison
mould to form the hollow parison. When the parison mold opens, both the parison and core are

Once the drums are blowed the extra part is removed and then it is sent for recovery process
where they are grinded into small granules and the they are mixed with the master batch and then
they are sent for melting process.

Caps are manufactured by injection moulding depending requirement different shapes

Generally 4 shapes are generally manufactured. 2000 closures are manufactured per day.

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Conclusion:

In this industry they are manufacturing the composite containers and HDPE drums which is of
good strength. Now days the demand for these Is increasing day by day. They fallow up all the
certifications and all the quality parameter testing is done in Indian institute of packaging (iip).

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 BHARADWAJ PACKAGING PVT LTD.

We went Bharadwaj Packaging that is corrugated fiber board manufacturing unit. There we seen
manufacturing process of CFB boxes with complete procedure from receiving raw materials to
finished goods and equipment’s used for production, additives added during production,
temperature maintenance and so on.

Bharadwaj packaging unit:

In that industry they manufacture corrugated fiber boxes of 3 ply, 5 ply and sometimes 7 ply
also. Usually they produce CFB of 90-300 GSM based on customer requirements.
Raw material: they receive raw material that is craft paper from different approved vendors.
Before accepting the craft paper, they check the quality parameters like GSM, compression
strength, COBB value, tensile strength. If the material has all the parameters within the specified
values then only they receive the raw material or otherwise they will reject.

Manufacturing process:
 Receiving the craft paper from approved vendor.
 Dwell press: it is the first machine used in manufacturing. It has two flutes one is broad
flute also called as A flute and another one is narrow flute called as B flute.

Before starting the production starch preparation is necessary. Starch powder, caustic
powder and borax are the materials used for starch preparation. This starch is used as a
gluing agent for attaching the flutes. Narrow end makes craft paper into flute of zig zag
shape. Sheets from broad end and narrow end moves along the machine. In between these
two sheets starch is applied automatically as a gluing agent. So that these two sheets are
attach each other and form a ply.
 Single press: here there is no broad flute. It has only narrow flute. Here another flute of
zigzag shape will produce to attach with older one.
 Double pressure/ gum machine: in this machine the flute from single press and the ply
from dwell press are attached with the use of glue. So make it into 5 ply.
 Heating/ hot plate section: after gluing of flutes the ply will be formed. This ply sheets
are passed into the hot plate section. It has 12 hot plates. Temperature maintained is to be
maximum of 150-160℃ and minimum of 90℃ . It has a continuous belt structure on that
the ply will move. The speed of production is 60 rpm. Here the ply gets its strength.
 Cooling section: it is also have a long belt for cooling the ply to atmospheric temperature.
No external aids are used for cooling.
 Slitting and scorer: here cutting of plies into required size will be done. It is depends on
the customer requirement.
 Printing machine: here 3 things have to be done. Printing, size cutting and bending.
Printing is done for print the company name, logo and other necessary information’s.
Size cutting and bending helps for further folding.
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  Automatic folding or stamping: automatic folding machine used to fold the ply by using
of glue. This glue is called as bond glue or food grade glue.

In stamping method the ply is folded manually and then stamping is done. Here they
don’t use any glue. For mass production automatic folding with usage of glue is better.

After folding of CFB boxes, bundles are made of 20-25 boxes each. And then supply to storage
unit or to the customer.

 The whole process of manufacturing corrugated fiber board takes 5-7 min.
 Production capacity is calculated in terms of line meter that is how much craft paper is
used in one minute. It is not measured in terms of tones. Because usage of craft paper will
be depends on which ply we are manufacturing and GSM of the ply.
Finished goods testing: after manufacturing the CFB boxes. They select samples randomly
from every batch. They do test of finished product for checking the required specifications.
Usually they carry out GSM, COBB test, compression strength and tensile strength.
All scrap and waste materials are collected and send to another recycling unit for further
processing.

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 AGI GLASPAC

The HSIL glass factory is established in 1972. HSIL (Hindustan sanitary ware and industrial
limited)

The HSIL is of two types

1. Building products division

2. Packaging division

1. Building products division :

a. Building products division
b. CPVC & UPVC
2. Packaging division

a. 2 glass manufacturing sections

b. 2 PET bottle section
c. 1 closures
The glass manufacturing section is under the brand of AGI glass
The pet bottle section is under the brand of GP (garden polymer)
The closures section is under the brand of AGI clozures .

Totally there are 900 employees. the glass division turnover is about 1000cr . bhonagiri plant is
the largest plant in India with 1000mt/day . In Hyderabad there are 11 lines working on it . In
bhonagiri plant there are 15 lines.
The product manufacturing range from 6ml to 4 litres bottles. Totally 500 varieties of glass
bottles are manufactured with different colours .

The percentage of their sales market is :

 Liquor – 48%
 Beer – 20%
 Food – 16%
 Pharma – 6.5%
 Soft drinks –1.5%
 Export – 8%

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The certification which the company acquired is:

FSSC 22000

OHSAS 18001

ISO 15378

ISO 14001

ISO 9001

TPM & LEAN 6 SIGMA

Batch processing:
Batch processing is one of the initial steps of the glass-making process. The batch house simply
houses the raw materials in large silos and holds anywhere from 1–5 days of material. Some
batch systems include material processing such as raw material screening/sieve, drying, or pre-
heating whether automated or manual, the batch house measures, assembles, mixes, and delivers
the glass raw material recipe (batch) via an array of chutes, conveyors, and scales to the furnace.
The batch enters the furnace at the 'dog house' or 'batch charger'. Different glass types, colors,
desired quality, raw material purity / availability, and furnace design will affect the batch recipe.

Furnace:
The hot end of a glassworks is where the molten glass is formed into glass products, beginning
when the batch is fed into the furnace at a slow, controlled rate by the batch processing system
(batch house). The furnaces are natural gas- or fuel oil-fired, and operate at temperatures up to
1,575 °C (2,867 °F). The temperature is limited only by the quality of the furnace’s
superstructure material and by the glass composition. Types of furnaces used in container glass
making include 'end-port' (end-fired), 'side-port', and 'oxy-fuel'. Typically, furnace "size" is
classified by metric tons per day (MTPD) production capability. Both methods, a stream of
molten glass, at its plastic temperature (1,050–1,200 °C [1,920–2,190 °F]), is cut with a shearing
blade to form a solid cylinder of glass, called a gob. The gob is of predetermined weight just
sufficient to make a bottle. Both processes start with the gob falling, by gravity, and guided,
through troughs and chutes, into the blank moulds, two halves of which are clamped shut and
then sealed by the "baffle" from above.

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Forming process :

In the blow and blow process, the glass is first blown through a valve in the baffle, forcing it
down into the three-piece "ring mould" which is held in the "neckring arm" below the blanks, to
form the "finish", [The term "finish" describes the details (such as cap sealing surface, screw
threads, retaining rib for a tamper-proof cap, etc.) at the open end of the container.] The
compressed air is blown through the glass, which results in hollow and partly formed container.
Compressed air is then blown again at the second stage to give final shape.
Containers are made in two major stages. The first stage moulds all the details ("finish") around
the opening, but the body of the container is initially made much smaller than its final size.
These partly manufactured containers are called parisons, and quite quickly, they are blow-
molded into final shape.
Referring to the mechanism, the "rings" are sealed from below by a short plunger. After the
"settleblow" finishes, the plunger retracts slightly, to allow the skin that's formed to soften.
"Counterblow" air then comes up through the plunger, to create the parison. The baffle rises and
the blanks open. The parison is inverted in an arc to the "mould side" by the "neckring arm",
which holds the parison by the "finish".
As the neckring arm reaches the end of its arc, two mould halves close around the parison. The
neckring arm opens slightly to release its grip on the "finish", and then reverts to the blank
side. Final blow, applied through the "blowhead", blows the glass out, expanding into the mould,
to make the final container shape.
In the press and blow process,the parison is formed by a long metal plunger which rises up and
presses the glass out, in order to fill the ring and blank moulds. The process then continues as
before, with the parison being transferred to the final-shape mould, and the glass being blown out
into the mould.
The container is then picked up from the mould by the "take-out" mechanism, and held over the
"deadplate", where air cooling helps cool down the still-soft glass. Finally, the bottles are swept
onto a conveyor by the "push out paddles" that have air pockets to keep the bottles standing after
landing on the "deadplate"; they're now ready for annealing.

Forming machines
The forming machines hold and move the parts that form the container. The machine consist of
basic 19 mechanisms in operation to form a bottle and generally powered by compressed
air (high pressure - 3.2 bar and low pressure - 2.8 bar), the mechanisms are electronically timed
to coordinate all movements of the mechanisms. The most widely used forming machine
arrangement is the individual section machine (or IS machine). This machine has a bank of 5–20
identical sections, each of which contains one complete set of mechanisms to make containers.
The sections are in a row, and the gobs feed into each section via a moving chute, called the gob
distributor. Sections make either one, two, three or four containers simultaneously. (Referred to
as single, double, triple and quad sgob). In the case of multiple gobs, the shears cut
the gobs simultaneously, and they fall into the blank moulds in parallel.

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Annealing:
As glass cools, it shrinks and solidifies. Uneven cooling causes weak glass due to stress. Even
cooling is achieved by annealing. An annealing oven (known in the industry as a Lehr) heats the
container to about 580 °C (1,076 °F), then cools it, depending on the glass thickness, over a 20 –
60 minute period.

Cold end
The role of the cold end is to spray on a polyethylene coating for abrasion resistance and
increased lubricity, inspect the containers for defects, package the containers for shipment,
and label the containers.

Inspection equipment
Glass containers are 100% inspected; automatic machines, or sometimes persons, inspect every
container for a variety of faults. Typical faults include small cracks in the glass called checks and
foreign inclusions called stones which are pieces of the refractory brick lining of the melting
furnace that break off and fall into the pool of molten glass, or more commonly oversized silica
granules (sand) that have failed to melt and which subsequently are included in the final product.
These are especially important to select out due to the fact that they can impart a destructive
element to the final glass product. For example, since these materials can withstand large
amounts of thermal energy, they can cause the glass product to sustain thermal shock resulting in
explosive destruction when heated. Other defects include bubbles in the glass called blisters and
excessively thin walls. Another defect common in glass manufacturing is referred to as a tear. In
the press and blow forming, if a plunger and mould are out of alignment, or heated to an
incorrect temperature, the glass will stick to either item and become torn. In addition to rejecting
faulty containers, inspection equipment gathers statistical information and relays it to the
forming machine operators in the hot end. Computer systems collect fault information and trace
it to the mould that produced the container. This is done by reading the mould number on the
container, which is encoded (as a numeral, or a binary code of dots) on the container by the
mould that made it. Operators carry out a range of checks manually on samples of containers,
usually visual and dimensional checks.

Secondary processing
Sometimes container factories will offer services such as labelling. Several labelling
technologies are available. Unique to glass is the Applied Ceramic Labelling process (ACL).
This is screen-printing of the decoration onto the container with a vitreous enamel paint, which is
then baked on. An example of this is the original Coca-Cola bottle. Absolut Vodka Bottles have
various added services such as: Etching (Absolut Citron/) Coating (Absolut Raspberry/Ruby
Red) and Applied Ceramic Labelling (Absolut Blue/Pears/Red/Black).
Packaging
Glass containers are packaged in various ways. Popular in Europe are bulk pallets with between
1000 and 4000 containers each. This is carried out by automatic machines (palletisers) which

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arrange and stack containers separated by layer sheets. Other possibilities include boxes and even
hand-sewn sacks. Once packed, the new "stock units" are labelled and warehouse.

Coating:
Glass containers typically receive two surface coatings, one at the hot end, just before annealing
and one at the cold end just after annealing. At the hot end a very thin layer of tin(IV) oxide is
applied either using a safe organic compound or inorganic stannic chloride. Tin based systems
are not the only ones used, although the most popular. Titanium tetrachloride or organotitanates
can also be used. In all cases the coating renders the surface of the glass more adhesive to
the cold end coating. At the cold end a layer of typically, polyethylene wax, is applied via a
water based emulsion. This makes the glass slippery, protecting it from scratching and stopping
containers from sticking together when they are moved on a conveyor. The resultant invisible
combined coating gives a virtually un scratchable surface to the glass. Due to reduction of in-
service surface damage, the coatings often are described as strengtheners, however a more
correct definition might be strength-retaining coatings.

Quality tests performed for glass bottles:

 Weight capacity
 Dimensions
 Thermal shock
 Vertical load
 Impact test
 Annealing
 Perpendicularity

Conclusion:

The glass is a generally a molten state where all the available raw materials are added like sand ,
soda lime etc and are heated to a high temperature and then the blowing is done to a bottle .
which can be reused for several times and which is 100% environmental friendly .

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 WINGS PAPER AND BOARD MILLS PVT.

About Company

 The main objective behind the visit was to make students aware about how
various activities related to recycle of used corrugated boxes, recycling and
manufacturing of recycled paper.
 The company is located at Medchal, Rangareddy (Dt.). As soon as we reached
there we were guided by one of the official of the company.
 Wings Paper and Board Mills Pvt. Ltd. has been established in the year 2011 with
an objective to cater to the market need for recycled paper. They are capable of
producing 40 GSM to 150 GSM and 16 BF to 30 BF Paper locally in India and
cater to global audience.
 Manufacturing recycled papers involves a multi stage process that starts with the
raw material of waste paper and ends with the final product of a recycled paper
that is comparable with virgin fiber papers both technically, aesthetically and on
press. They manufacture paper by recycling the used corrugated boxes and paper
which are collected form malls, industries etc.
 In the first step they prepare pulp by sorting waste paper dispersed in water in the
pulper to separate fibers and ink and other components. Next screening is done by
cyclonic purification which allows complete elimination of all contaminants and
non-fibrous materials such as minerals, needles, glass pieces, pins etc.,
 The next step involved in recycled paper manufacturing is De-inking. Ink is
extracted from pulp mix through floatation by blowing air from bottom. Extracted
ink is skimmed from the surface. Then the pulp is sent into boiler section and pulp
is cooked with baking soda and adhesives to develop bond between fibers and the
cooked pulp is poured into head box. Adding Alum & Rosin will increase the
sizing properties of the paper produced.
 The pulp mix is poured from the ‘head box’ onto a wire mesh usually made from
nylon called 'the wire'. The fibers mesh together on the wire whilst water is
drained to form the sheet. Water is collected, recycled and ultimately treated prior
to being returned to the environment often cleaner than when extracted.

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 As the water drains, the pulp mesh becomes a wet paper base. The paper base is
fed into the press section where it is pressed between two absorbent cylinders to
extract more water. Then the wet paper is passed through drying section in which
wet paper is rolled to a big drum like roller which is heated using external source
of heat and the paper is completely dried. Cooling arrangement is done to bring
the paper temperature to room temperature.

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 The steps including in paper manufacturing are:
 Pulping: the raw materials cut into small pieces and fed into the pulper. It is chamber having
blades and outlets. Blade helps to cut the material into small pieces. Outlet helps to removal of
plastic materials and cullet’s if mixed with paper. Here, the raw material is mixed with sufficient
water. Water used should be hot. They add caustic, lime and other chemicals, these helps to
proper pulping.
 Secondary chamber: after pulping the pulp may store in this chamber for some times based on
production requirements.
 Refiner: from storage tank pulp moves to refiner. Refiner connected with filter of 0.2mm.
Materials having size less than 0.2 mm passed into refiner. In refiner rollers are provided, which
separates out the fiber from the pulp. So as to make into a thick paste.
After refining, they check the quality parameters of pulp by doing some basic experiments.
 Thickener: after refining, the pulp is sent to thickener. Here pulp will be separates from water.
After thickener the pulp may store for some times otherwise send to cooking.
 Cooking of pulp: the pulp is cook to get proper consistency. The pulp will cook for prescribed
temperature and time. During cooking they add caustic, alum and resins. Alum helps to maintain
the pH of pulp. Resin helps to increase the quality of pulp. The proper consistency of pulp is
made before sending to the header.
 Header: header has a spray like structure for spraying pulp. It sprays the pulp on a continuous
long belt. This belt has pores in that so that the excess water sucked out through these pores by
using vacuum.
 Press: 2 presses are present. Each press having 2 rollers in that one is made of rubber and
another is steel roller. In these presses, pressing of paper will done and also helps to removal of
water to some extent.
 Steam roller: after pressing the paper sheet is passed to the steam roller. Is has connection with
pipe through which hot steam will be sending to the inside of the roller. So that the surface of the
roller becomes hot. Here evaporation of water takes place to attain the required temperature of
paper. Steam is maintained at a pressure of 7.5 Kg/cm2.
 Cooling: for cooling a big fan is provided. Rather than cooling it helps in removing the
evaporated water so that avoiding the condensation of water. This step is very much necessary

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 because if water is condensed means that water will fall down on paper. It makes damage of
paper and affects the quality of paper.
 Machine Glazed Cylinder: Side of the paper which is in touch with MG Roll Side will have
Smooth finish. The other side will be rough finish surface.

 Slitter: After cooling the paper makes into big bundles. Then it will cut into required size as per
customer’s requirement. Minimum trim of 20-30 mm on both sides of the big bundles to cut in to
required shape.
 Big Bundle Size – Size of Small Bundle*N(No. of Steps) + 2*30mm

Quality Tests Performed:

GSM, COBB Test, Bursting Strength and Burst factor.

Capacity of the Plant:

1500 Tons per Month.

Packing of Rolls:

 Manual Packing with strapping wire.

 Roll is manually weighed and sticker is pasted on the roll for tracking purpose.
 Sticker includes following details like Reel No., Roll No., and GSM of the Roll and Size of the
Roll.

Images are taken from http://www.wingspapers.com/about-us.html

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REFERENCE:

https://recycled-papers.co.uk
http://www.wingspapers.com

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