Training syllabus for Quality Assurance at Corrugation Plant

S.no Modules Time

1` Introduction of Corrugation and basic knowledge

 What is a corrugated box ?
 What is a flute and it’s types ?
 Types of kraft papers used in the company
 What is a starch based adhesive ?
 How the corrugation process works ?
 What is pantone color standard ?
 What is a ISO , SOP standard and how they are used in our company
?
 What is 5S ? and how it is applied here.
 Different properties of paper and board.

2 Evaluation of product and process

 Procedure for online inspection on plant , Printing and gluing
 Different type of defects and to locate them
 Procedure for approval for printing
 Procedure of wastage and production monitoring
 Procedure for customer complaint analysis
 Paper incoming process

3 Soft skills
 BOM Entry
 COA report creation
 Communication skills
 Batch code generation
 Job Card creation
 Different formula used in company for Calculation Of GSM , BF and so
on
 Statistics

4 Machinery
 What type of printing machine we use in the company?
 What type of plant we use? And complete analysis of each section of
what and how it works.
 Units to for measurements used in Lab and in plant

MODULE 1 : Introduction of Corrugation and basic knowledge

1. What is a corrugated box ?

A corrugated box or called as a carton is packaging container made up of kraft paper by a

corrugation process followed in the corrugation plant.

This corrugation process results in cartons like 2ply, 3 ply , 5 ply, 7ply. Ply simply means layers of
kraft paper between any 2 layers of paper there is layer called flute .

2. What is a flute? and it’s types

A flute is the most fundamental layer in the carton it is the layer which gives board it’s strength
and structure different type of boards according to their requirement require different type of
flutes like A , B , C ,E and on . E-flute is ideal for high quality printing with a thickness of 0.9-1.7 ″.
It is generally used for mailers and some specialty displays like the beer and wine cases. B-flute
 is a good alternative to E-flute when wanting to support heavier items. With a thickness of 2.1 -
2.6 and shorter flutes, this type of box still provides a rigid, flat surface for printing. C-flute is
commonly used for shippers. The flutes are taller here at 3.3 – 3.8, giving C-flute somewhat
better cushioning properties than B-flute.

3. Types of kraft paper used in the company

 Natural Brown
 KLB Gold
 Natural gold
 HRCT
 Agro
 Waste to waste

4. What is a starch based adhesive?

Starch adhesives are readily available, low in cost, and easy to apply from water dispersion. They
are considered to be the least expensive class of paper packaging adhesive. Formulated starch
adhesives can be applied hot or cold, but generally are used hot. They have excellent heat
resistance. Disadvantages include poor moisture resistance and mold growth.

5. How corrugation process works?

The corrugation process with the kraft paper required as per the customer demand. For
example a customer can ask for a 24 BF paper with Gold shape on top. So you have to do that
accordingly .Once you have your reels on the reel stand than operator at the corrugation
machine will begin to start putting the paper from the Flute reel into the machine
simultaneously from the liner. Corrugation begins at the corrugator also called “Single facer”
than it gets transferred to the pasting operator also called as “Double facer”. Where the pasting
operator applies Starch based adhesive on the layers of the board so that it can become a ply.
Which then again get forwarded to the rotary operator who applies the required flap size and
benders with the help of rotary machine.