A Journey Shaped by Paper, Process, and People
Over the past 20 years, my journey in the corrugated packaging industry has taken me across manufacturing plants, technology centers, and training facilities throughout Europe, the UK, the Middle East, and Asia.
Through commissioning projects, process optimization, operator training, and benchmarking visits, I have had the privilege of learning from some of the world’s leading corrugated packaging companies, including Smurfit Kappa, WestRock, International Paper, Saica, Dunapack, DS Smith, Mondi, CorrBoard UK, and Klingele.
Despite different technologies, operating cultures, and manufacturing philosophies, one lesson has remained constant:
“A corrugated board is never just a carton box.”
To the customer, it is simply packaging.
To those of us on the corrugator floor, it is the result of science, engineering, teamwork, experience, and hundreds of process decisions made every shift.
THE CLAY POTTER’S LESSON
I often compare our profession to a skilled clay pot maker.
Watching a master potter shape clay on a spinning wheel looks effortless. The clay spins, the hands move, and a beautiful pot emerges.
Simple.
Until you try it yourself.
Only then do you realize the years of practice, precision, patience, and craftsmanship required to create something exceptional.
Corrugating is exactly the same.
People see paper entering a machine and board coming out.
What they don’t see is the science, process control, troubleshooting, and operational expertise required every minute of every shift to consistently produce high-quality board.
THE FOUR PILLARS OF CORRUGATOR EXCELLENCE
PAPER
The Foundation
Understanding fiber quality, moisture, strength properties, and paper behavior is the first step toward stable production and consistent quality.
HEAT
The Energy
Heat drives flute formation, moisture balance, starch activation, and ultimately board performance.
STARCH
The Bond
The right starch formulation, viscosity, and application create strong, reliable bonding and structural integrity.
MACHINE PARAMETERS
The Control
Speed, pressure, temperature, glue settings, and machine discipline must work together in harmony.
TECHNOLOGY HELPS. PEOPLE MAKE THE DIFFERENCE.
Over the years, I have witnessed the industry’s evolution from traditional manufacturing methods to highly automated and data-driven operations.
Today’s corrugators are equipped with advanced controls, automation, analytics, and real-time monitoring systems.
Yet one truth remains unchanged:
“Machines make boards. People make quality boards.”
The best operators and engineers know how to read the paper, understand the process, anticipate problems, and react before quality is affected.
That knowledge is not found in manuals.
It is earned through experience.
A PERSONAL REFLECTION
Looking back, what I value most is not the machines I have commissioned or the production records achieved.
It is the people.
The mentors who guided me.
The operators who shared practical wisdom.
The technicians who solved difficult challenges.
The teams who transformed obstacles into achievements.
Every plant visit, startup, troubleshooting session, and training program has added another lesson to my journey.
FINAL THOUGHTS
The customer sees a box.
We see paper science, heat transfer, starch chemistry, process engineering, teamwork, and craftsmanship coming together within seconds.
We are not simply manufacturing packaging.
We are transforming paper into performance.
After more than two decades in this remarkable industry, one thing has become clear:
Corrugating is not just my profession. It is my passion.
ABOUT THE AUTHOR
Rajeev P.S. has more than 20 years of international experience in corrugator operations, process optimization, machine commissioning, operational excellence, technical training, and manufacturing leadership. His professional journey includes exposure to world-class corrugated packaging operations across Europe, the UK, the Middle East, and Asia, working alongside some of the industry’s most respected organizations and professionals.
