Amit Shah of Spectrum Scan set the tone for the discussion on the roundtable by saying that regardless of the growth or degrowth of mono carton packaging, corrugated packaging will thrive. “Why do I say that? Anything that needs to be shipped will need corrugated shipper boxes. However, corrugation applications are not just restricted to shipper cartons. There are many applications which have more to do with science and planning than the simple shipper boxes one is thinking of,” he said.

With the growing trend of online shopping, corrugated boxes are extensively used for packaging products purchased online. “What Amazon did during Covid-19 lockdowns is amazing,” said Shah.

According to market research reports and industry estimates, the Indian corrugated packaging market has been growing at a CAGR (Compound Annual Growth Rate) of around 15-20% over the past few years. It is estimated that India's corrugated packaging market was valued at around Rs 30,000-35,000-crore (approximately USD 4 to 5-billion) in 2020, and is expected to continue growing at a healthy pace in the coming years.

Shah said, sector’s growth is driven by various end-use sectors, including FMCG (fast-moving consumer goods), food and beverages, eCommerce, textiles, automotive, pharmaceuticals, and more. “The demand for corrugated boxes in India has been primarily driven by their advantages such as lightweight, cost-effectiveness, recyclability, and versatility in packaging a wide range of products.”

Design and packaging methods for corrugated boxes involve several steps to create functional and appealing packaging solutions, said Tushar Pande of Emerging Graphics. “The design of the corrugation box determines how strong, durable and functional the box will be. What is important is that with corrugation, one can tailor its needs to specific products being packaged taking into consideration its size, weight and fragility.”

Computer-aided design (CAD) software is used to create precise box templates that can be easily cut and scored on corrugated cardboard sheets. “Die-cutting and creasing methods are put to use. There are conventional as well as digital equipment for both long and short-run jobs,” said Pande, who company Emerging Graphics provides EngView CAD software, flatbed inkjet printers to print on corrugated sheets from 1.5mm to 30mm thick corrugated sheets as well as Lecho digital cutting machines.

The structural integrity of corrugated materials is crucial in ensuring that packaging can withstand the rigours of the supply chain, said Manish Shah of  Acme Machinery. Shah discussed the need for different use of paper to manufacture corrugated sheets. “Anything that can help better surface finishing to maintain strength, as well as use of food grade paper to cater to pharma and food business will be a game-changer for the sector,” he said.

To summarise, Shah of Spectrum Scan said, “Advancements in technology will make corrugation an option for secondary carton packaging. It has the potential to replace plastics for displays. However, there is a need to have good quality Kraft paper.”