Corrugated Carton Production Line and Factory Setup

A corrugated carton production line is a complete industrial system designed to produce corrugated board, print, die-cut, glue and pack cartons under controlled process conditions. The line produces shipping and retail cartons from kraft paper.

From an industrial perspective, carton manufacturing is important because it combines precise corrugation, accurate printing, controlled die-cutting and reliable gluing to achieve consistent strength, print quality and dimensional accuracy. The process relies on a defined sequence of unit operations that must be correctly engineered, sized and integrated.

Primary materials typically include kraft paper, waste paper, starch adhesive and printing inks. The core machinery set consists of corrugators (width 100–2200 mm), flexo printers (1–4 colours), die-cutters, gluers and strapping machines.

The Industrial Department supports investors who want to establish a new carton plant as well as existing operators who need repair, overhaul, capacity expansion or automation of their current lines. Projects can start from an empty site or from an operating facility that requires technical upgrading.

Whether the goal is a green-field turnkey carton plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The corrugated carton line is engineered as an integrated process system covering board production on the corrugator, flexo printing, die-cutting, gluing, strapping and packaging. Design capacity is determined during the engineering phase and can typically range according to corrugator width and speed (small models around 3–6 cartons per minute).

Main machinery groups include corrugators, flexo printers, die-cutters, gluers and strapping machines. Supporting infrastructure covers electrical power, gas and process water.

Manpower requirements depend on the degree of automation. Quality control covers board strength, print quality and dimensional accuracy.

Technical Specifications

Specification	Description
Product	Corrugated shipping and retail cartons
Production Capacity	Depending on corrugator width and speed (small models 3–6 cartons/min)
Required Area	500–1000 m²
Electrical Power	380 V three-phase, 100–200 kW
Gas	50–100 m³/h
Water Consumption	5–10 m³/day
Manpower	8–15 persons per shift
Corrugator Width	100–2200 mm
Main Machines	Corrugator, flexo printer, die-cutter, gluer, strapping machine

All figures are indicative.

Products

Corrugated cartons in various flute types, board grades and print designs for shipping and retail use.

Raw Materials for Carton Factory

Primary materials are kraft paper, waste paper, starch adhesive, printing inks and packaging materials.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of kraft paper, adhesives and inks required by carton plants.

Registering an order for raw materials for the factory Carton
Sahi Rasa Supply Chain Department

Support is available for projects in Iran, Iraq, Kurdistan Region, Afghanistan and other regional markets.

Manufacturing Process

1. Board Production – Kraft paper is converted into corrugated board on the corrugator.
2. Printing – Board is printed by flexography (1–4 colours).
3. Die-Cutting – Cartons are cut to shape.
4. Gluing – Edges are glued.
5. Strapping and Packaging – Finished cartons are strapped and packed.

Machinery & Equipment

• Corrugator – Produces corrugated board (width 100–2200 mm). Position: first stage. Importance: board strength and capacity. Quality impact: incorrect flute or adhesion reduces strength. Maintenance: fluting rolls, glue systems and heaters. Sahi Rasa support covers design, installation, repair and spare parts.
• Flexo Printer – Applies print (1–4 colours). Position: after board production. Importance: branding and identification. Quality impact: poor registration affects appearance. Maintenance: plates, anilox rolls and ink systems.
• Die-Cutter and Gluer – Cuts and joins the carton. Position: mid-line. Importance: dimensional accuracy and assembly. Quality impact: inaccurate cutting or weak glue joints cause failures. Maintenance: dies, knives and glue applicators.
• Strapping Machine – Secures finished cartons. Position: end of line. Importance: logistics. Quality impact: incomplete strapping causes damage in transit. Maintenance: tensioners and sealing systems.

Factory Layout & Building Requirements

Typical areas include paper storage, corrugator hall, printing, die-cutting and gluing, finished-goods storage, quality control, utilities and staff facilities. Exact area is determined during engineering.

Utilities

• Electricity: 380 V three-phase, 100–200 kW
• Gas: 50–100 m³/h
• Water: 5–10 m³/day

Turnkey Factory Setup

An investor can start from an empty site. The project can be accompanied through feasibility, engineering, design, machinery, installation, commissioning, training and commercial production.

EPC & PMC

Projects can be executed under EPC or PMC approaches within defined contracts.

Machinery Repair

Existing carton lines can request inspection, repair and spare-parts support for corrugators, printers, die-cutters and gluers.

Machinery Overhaul & Refurbishment

Older equipment can be overhauled and control systems upgraded.

Capacity Expansion

Capacity can be increased by upgrading the corrugator or converting capacity.

Industrial Automation

PLC control of speed, glue application and cutting is typical.

Supply Chain

The Supply Chain Department supports kraft paper, adhesive and ink supply.

Packaging

Finished cartons are strapped and stacked according to market requirements.

Branding & Product Development

Support for print design and technical documentation is available when required.

Market & Country Sections

Services are available in Iran, Iraq, Kurdistan Region, Afghanistan and other listed regional markets.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment
Factory Design	Layout and process design
Machinery Design / Manufacturing	Equipment specification and supply
Procurement	Sourcing of machinery and materials
Installation & Commissioning	Start-up and testing
Automation	PLC and process control
Raw Material Supply	Via Supply Chain Department
Repair / Overhaul	Restoration of existing equipment
Capacity Expansion	Throughput increases
Staff Training	Operational training

Why Sahi Rasa

Integrated process engineering, machinery, installation and training provide a clear path from concept to operating production line.

From Empty Land to Production

Typical sequence from feasibility through commercial production.

Who Should Contact Sahi Rasa?

• Investors planning a new carton plant
• Existing owners needing repair, overhaul or expansion
• Industrial buyers requiring machinery or materials

Final CTA

Contact the Industrial Department for factory setup, machinery, repair, overhaul or raw-material coordination.

Registering an order for raw materials for the factory Carton

FAQ

1. What capacity can be designed?
   Depending on corrugator width and speed.
2. Which main machines are required?
   Corrugator, flexo printer, die-cutter, gluer and strapping machine.
3. How much space is needed?
   Approximately 500–1000 m².
4. Can existing lines be repaired?
   Yes.
5. Are turnkey projects available?
   Yes under defined contracts.
6. Are services available in Iraq and Afghanistan?
   Yes.
7. Can kraft paper be supplied?
   Yes via the Supply Chain Department.
8. Is installation included?
   It can be included according to the package.
9. What about automation?
   PLC and process control can be provided.
10. How is capacity expanded?
    By upgrading the corrugator or converting capacity.