Sustainable Packaging Solutions: The Future of Corrugation

An Overview of the Corrugated Box Manufacturing Process

Have you ever wondered how the humble corrugated box is made? These versatile and durable boxes are used for packaging and shipping countless products worldwide, from your favorite pizza to your latest online shopping haul. In this blog post, we’ll dive into the fascinating step-by-step process of converting corrugated board rolls (reels) into corrugated sheets and then into finished cartons and boxes. Let’s get started!

Step 1: Cutting Corrugated Sheets

The journey of a corrugated box begins with corrugated board rolls, also known as reels. These rolls are fed into a cutting-off machine, which trims the reels into corrugated sheets of the desired size. This crucial step ensures that the raw material is ready to be transformed into the sturdy and customizable boxes we know and love.

Step 2: Flexo Printing for Eye-catching Designs

Once the corrugated sheets have been cut, they are ready to be beautified. The sheets are placed into a flexo printing machine, which prints the desired graphics on their surface. This could include company logos, product information, or even intricate designs to make the box stand out on the shelf. The result? A visually appealing and informative package that catches the consumer’s eye.

Step 3: Slitting and Scoring for Precision Box Dimensions

Next up is the process of slitting and scoring. The printed paper sheets are transported into the slitter and scorer machine, which performs two essential functions:

  1. Slitting: The machine trims the sheets into the required width of the corrugated box.
  2. Scoring: The machine creates grooves in the sheets, forming flaps that will later be used to construct the box.

These processes ensure that the sheets have the exact dimensions necessary for the final corrugated box. 

Step 4: Selecting the Right Machine for Different Cartons and Boxes

Depending on the customer’s needs and the type of product being packaged, different machines are used to produce a variety of cartons and boxes. For example:

  • If a customer requires a regular slotted carton box for shipping or packaging purposes, an automatic slotter and creaser machine (slotting and creasing machine) would be used.
  • If a customer needs a special-shaped box for items like pizza, shoes, cups, or jewelry, a rotary die-cutting machine for corrugated boxes would be the machine of choice. This machine requires specific dies to cut the corrugated sheets into the required shapes. Changing the die on the die-cutting roll allows for the production of different cartons.
Step 5: Stitching or Gluing the Flaps to Create the Final Box

Once the corrugated sheets have been slotted or die-cut, the last step in the process is to assemble the box. The flaps of the corrugated box blanks are stitched or glued together, creating the final cartons or boxes that are ready to be filled with products and shipped off to customers.

And that’s a wrap! By understanding the intricacies of the corrugated box manufacturing process, we can appreciate the engineering and craftsmanship that goes into creating these essential packaging solutions. Next time you receive a package, take a moment to admire the humble corrugated box that has been designed and crafted to protect its contents and ensure safe delivery.

The Role of Automation in Corrugated Box Manufacturing

As the demand for corrugated boxes continues to grow, manufacturers are increasingly Incorporating automation to streamline the production process and meet customer needs more efficiently. Let’s take a look at how automation has revolutionized the corrugated box manufacturing industry.

Improved Efficiency and Productivity

Automation has enabled manufacturers to produce corrugated boxes faster and with greater precision, resulting in increased efficiency and productivity. Incorporate solutions for optimizing planning, to manage their entire enterprise in one platform where the data flows seamlessly, collecting data to make proper decisions through insights.

Enhanced Customization and Flexibility

With automated processes, manufacturers can easily switch between different box designs and sizes, allowing them to cater to the diverse needs of their clients. This flexibility is particularly beneficial in today’s fast-paced market, where businesses often require packaging solutions that are tailored to their specific products and branding.

Reduced Waste and Environmental Impact

Automation has also helped corrugated box manufacturers minimize waste and improve their environmental footprint. By optimizing the use of raw materials and cutting down on excess production, automated processes result in less waste and a more sustainable manufacturing process.

The Future of Corrugated Box Manufacturing

As the corrugated box manufacturing industry continues to evolve, we can expect to see even more innovations and technological advancements that will shape the future of packaging. From the development of new materials to the integration of smart technologies, the possibilities are endless.

Sustainable and Eco-friendly Materials

As environmental concerns become increasingly important, the development of sustainable and eco-friendly materials will play a crucial role in the future of corrugated box manufacturing. Researchers are exploring the use of renewable resources, such as cellulose fibers from agricultural waste, to create more sustainable corrugated packaging solutions.

Smart Technologies and IoT Integration

The integration of smart technologies and the Internet of Things (IoT) into the corrugated box manufacturing process has the potential to revolutionize the industry. By connecting machinery and equipment to the internet, manufacturers can monitor and analyze production data in real-time, allowing them to optimize processes, reduce downtime, and improve overall efficiency.

Personalized and Interactive Packaging

As consumers increasingly seek personalized and unique experiences, we can expect to see corrugated boxes that feature interactive elements and customized designs. Augmented reality (AR), QR codes, and near-field communication (NFC) technologies offer exciting opportunities for brands to engage with their customers through innovative packaging solutions.

Transforming the Corrugation Industry with Our Comprehensive ERP Solution

The corrugation industry plays a crucial role in the global economy, supplying essential packaging materials to businesses worldwide. Manufacturers must continually improve their processes, reduce costs, and adapt to evolving market demands to stay competitive. That’s where our innovative Enterprise Resource Planning (ERP) solution comes into play. In this blog post, we’ll explore the key modules of our ERP system specifically designed to streamline operations in the corrugation industry.

Key Modules for the Corrugation Industry from Our ERP

Our ERP solution offers a range of modules that cater to the unique needs of corrugated box manufacturers, ensuring maximum efficiency, accuracy, and profitability. Let’s dive into the essential modules that make our ERP system the perfect choice for businesses in the corrugation industry.

1. Purchase Module

The Purchase Module simplifies the procurement process by automating tasks such as raising requests, generating quotations, and tracking purchase orders. This module centralizes essential procurement information, like supplier data, contract terms, and pricing, allowing manufacturers to make informed decisions and streamline their purchasing activities.

2. Production Module

Efficient production planning is vital to corrugated box manufacturers, and our Production Module helps businesses optimize their operations. By considering machine specifications, raw material lead time, and other constraints, this module enables manufacturers to plan production effectively while prioritizing on-time delivery. Additionally, it offers real-time updates on the production process, ensuring smooth and efficient workflows.

3. Fixed Assets Module

The Fixed Assets Module provides detailed information on all fixed assets within an organization, including total cost, useful lifetime, and scrap value. This module simplifies transactions related to fixed asset purchases, sales, and transfers, while also calculating depreciation for accurate financial reporting.

4. Maintenance Module

The Maintenance Module is designed to keep critical assets, such as machinery and vehicles, in optimal condition through preventative maintenance. This module ensures that equipment is always ready for operation, reducing opportunity costs and maximizing productivity.

5. Finance Module

Our Finance Module manages all financial operations within an organization, offering a comprehensive view of the company’s financial status. By automatically tracking and posting transactions to the relevant ledgers, this module makes financial management seamless and efficient. Customizable financial reports, including income statements, balance sheets, and cash flow statements, empower managers to make data-driven decisions.

6. Sales Module

The Sales Module streamlines the entire order fulfillment process, from order placement to delivery. With real-time tracking of orders, shipments, and delivery statuses, this module helps manufacturers ensure timely deliveries and maintain accurate inventory levels.

Custom Modules for the Corrugation Industry from Our ERP

In addition to the core modules mentioned above, our ERP solution offers custom modules tailored to the specific requirements of the corrugation industry. These modules tackle unique challenges faced by corrugated box manufacturers, further enhancing their operational efficiency.

1. Pre-Costing Module

Our Pre-Costing Module help corrugated manufacturers to do accurate cost estimation by taking into account the raw material (paper consumption, Ink, etc.) required, labor cost, and other overhead costs. This information will help the management to take informed decisions about pricing and profitability.

Pre-costing module can also assist in choosing the appropriate reel size for the orders. In addition to that, this module can be used to set budgets for the corrugation manufacturing process, and also to forecast future expenses based on historical data.

2. Quality Control Module

The Quality Control Module ensures that quality standards are consistently maintained throughout the manufacturing process. The quality control module can help in defining and standardizing quality parameters for raw materials, work-in-progress (WIP), and finished products.

Also, this module can provide real-time monitoring of the manufacturing process, allowing operators to identify any quality issues as they arise. This can help minimize defects and ensure that products are manufactured to desired quality levels.

This module generates the checklist for every step in the manufacturing process which needs to be supervised. By reviewing this checklist, manufacturers can reduce the number of defective products that are produced and also control defective products getting delivered to the customers.

3. Die Cut and Block Handling Module

The Die Cut and Block Handling Module streamlines the die-cutting and block-handling process for orders that require custom shapes and designs. By managing the availability of designs, blocks, and dies, this module helps manufacturers optimize their operations and reduce lead times.

Checking the availability of designs and blocks, developing new blocks/ designs, and any other activity is facilitated by this module. This includes everything from designing the die to programming the cutting machine to cut the corrugated material. By automating these steps, manufacturers can reduce the risk of errors and inconsistencies, and ensure that each product is cut to the exact specification required.   

4. Inventory Module

Effective inventory management is crucial for corrugated box manufacturers, and our Inventory Module delivers real-time information on inventory levels. This module helps businesses plan and procure raw materials more efficiently, ensuring a smooth and uninterrupted manufacturing process.

The inventory module offers advanced inventory management features such as categorizing reels based on type and size, allowing for better organization and tracking. Real-time inventory data enables manufacturers to avoid overstocking or understocking, reducing the risk of stockouts.

Additionally, this module provides valuable insights into the usage of paper reels, including the number of reels used in a given period, the length of time each reel was in use, and the amount of waste generated during production. By analyzing this data, manufacturers can identify areas for improvement and make adjustments to their processes to boost efficiency and minimize waste.

APS and BI tools for Corrugation Industry

Manufacturers in the corrugation sector need to ensure efficient processes, reduced costs, and adapt to changing market demands to remain competitive. Advanced Planning and Scheduling (APS) and Business Intelligence (BI) tools are two powerful solutions that can help corrugated manufacturers overcome these challenges.

APS for corrugation Industry
1. Accurate Production Planning

The primary benefit of APS software is accurate production planning. Corrugated manufacturers can use APS software to create a detailed production schedule that takes into account the availability of raw materials, machinery, and labor. With APS software, manufacturers can optimize their production schedule to minimize idle time, reduce setup times, and maximize throughput.

2. Improved Production Efficiency

By optimizing production schedules, APS software can improve production efficiency. With accurate production planning, manufacturers can minimize the time spent on setup and changeovers, thereby reducing downtime and increasing machine. Additionally, APS software can help manufacturers to identify bottlenecks in their production processes and allocate resources to improve efficiency.

3. Reduced Inventory cost

Accurate forecasting is enabled through the errorless data collected in the system, which helps manufacturers to reduce the number of raw materials and finished goods held in inventory. This helps to reduce the cost of carrying inventory and frees up valuable warehouse space. APS provides an accurate plan that enables the procurement department to provide delivery dates of materials. exactly when the material has to be delivered by the supplier is facilitated by APS.

4. Increased Customer Satisfaction

With APS software, corrugated manufacturers can improve their delivery times and increase customer satisfaction. By optimizing production schedules, manufacturers can ensure that orders are delivered on time and in full, which helps to build customer loyalty.

5. Enhanced Decision Making

APS software provides corrugated manufacturers with real-time data on production processes, which can be used to make informed decisions. By analyzing production data, manufacturers can identify areas for improvement and optimize their production processes. This helps to reduce costs, improve efficiency, and increase profitability.

BI for corrugation Industry
1. Data Analysis

Qlik enables the industry to analyze vast amounts of data quickly and easily. This can help manufacturers to identify patterns and trends in their operations, allowing them to optimize their processes. Ex; the BI tool can help manufacturers to identify the most efficient production processes and make changes to improve efficiency.

2. Real-Time Monitoring

Qlik tool allows manufacturers to monitor their operation in real-time. This helps them to identify issues as they occur, enabling them to take corrective action quickly. For example, if a machine is down or there is a problem with raw materials, BI tools can alert manufacturers, enabling them to resolve the issue before it affects production.

3. Improved Decision-Making

Qlik tools provide manufacturers with insights that enable them to make informed decisions. For example, BI tools can provide data on inventory levels, production schedules, and sales trends, helping manufacturers to make decisions that improve their operations. This can help manufacturers to reduce costs, improve efficiency, and increase profitability.

4. Performance Management

Qlik tool enables the corrugation industry to monitor and manage the performance of their operations. This can help manufacturers to identify areas for improvement and make changes that improve their efficiency. For example, Qlik can provide data on machine downtime, helping manufacturers to identify bottlenecks in their production processes.


Our comprehensive ERP solution is designed to meet the unique challenges faced by the corrugation industry. By offering a wide range of modules tailored to the needs of corrugated box manufacturers, our ERP system helps businesses streamline operations, reduce costs, and adapt to changing market demands. If you’re interested in learning more about our ERP solution or scheduling a demo, please contact us to discover how we can help transform your corrugation business.