Board in. Box out.

1. 

   01

   Corrugation

   Flute paper is heated, formed and bonded between liners to create the board structure. The flute profile determines how the sheet behaves under compression.

2. 

   02

   Cutting

   Sheets are cut to a repeatable blank size before printing or conversion. The cut plan is checked against the finished box dimensions and the usable sheet.

3. 

   03

   Printing

   Rubber-die flexo printing can add handling marks, product information and brand ink. Print coverage is agreed before the run starts.

4. 

   04

   Pasting

   Gum is applied to the joining flap and folded under pressure. The joint must hold through packing, stacking and transport.

5. 

   05

   Scoring

   Score lines create clean folds without crushing the board around the crease. Score position is set from the finished internal dimensions.

6. 

   06

   Slotting

   Slots are cut for flaps and closing panels. Blade settings change with the ply and board thickness, especially on heavy cartons.

7. 

   07

   Punching

   Cut-outs, handles and ventilation openings are made with a die fitted to the blank. The cut pattern is checked for clean release.

8. 

   08

   Stitching

   For heavy cartons, wire stitching gives the joint more holding power. The stitch line is kept clear of the product and the closing flap.

9. 

   09

   Waste management

   Trim and offcuts are separated for recycling instead of mixed disposal. Usable offcuts can also support internal packing work.

Images illustrate standard corrugated conversion stages. Photographs of the Narsingi line are available on a factory visit.