Manufacturing Process >> Coated Duplex Boards

N. R. Agarwal Industries Ltd oup manufactures Double Coated Duplex Board (Heavy Weight Coated) - Grey Back and White Back in three different Production Units situated at Vapi, Gujarat. The orders are received from Distributors and Customers in various GSMs and Sizes. All orders are sorted out first by GSM and then by sizes. Orders in a particular GSM range are matched so as to suit the machine deckle before finalizing the manufacturing program of that particular GSM range.

The Group manufactures Double Coated Duplex Board - HWC (White Back) at N.R.Paper & Boards Ltd., Superior Quality Double Coated Duplex Board - HWC (Grey Back) at N.R.Agrawal Industries Ltd. - Unit I and economic quality Double Coated Duplex Board - HWC (Grey Back) at N R Agrawal Industries Ltd - Unit III. Machine deckles are 252 cm, 166 cm & 168 cm at N. R. Agarwal Industries Ltd. - Unit I, N R Agrawal Industries Ltd - Unit III and N R Agrawal Industries Ltd - Unit IV respectively.

Normally, Duplex Board consists of multi-layered formation including three basic layers called Top Layer, Protective Layer and Bottom Layer. In the manufacturing process, 7 moulds/foamers are used for getting good formation of individual layers and better bonding potential between various layers of the board manufactured. All production is based on recycled fibres.


Apart from replacing moulds by formers at N. R. Agarwal Industries Ltd. - Unit I, the manufacturing arrangement also has press suction and dryers, which are arranged in a well defined sequence for drying of the board, before and after coating for maintaining the uniform range of moisture as per international standards a BMB blade coater is installed on top coat. Finally, the board is rolled as parent roll after passing through the latest calendaring system.


During the manufacturing process, highly skilled technicians equipped with right technology maintain the International Standards of Brightness, Gloss, Ply-bond, IGT, Surface pH, Stiffness, Caliper, Bulk, SOAT Value and Cobb (top & bottom) for getting the goods print gloss and print depth. Board thus produced, is suitable for all types of offset multi-coloured printing, followed by varnishing, poly-lamination, if required, and for the blister packaging as per the requirements of various customers.

Manufacturing capability of the board ranges from 200 to 500 GSM as per the requirement of the market, keeping all the required parameters under strict control, for getting the best results for our esteemed clients. Appropriate equipment is maintained with facilities for lifting the goods from godowns to loading points. Company is also in a position to supply the material in the pallet packing / ream packing as per the requirement of the international customers.

Production facility at N. R. Agarwal Industries Ltd. - Unit I is equipped with latest technology with respect to the formation where manufacturing process uses 7 formers for getting good formation and better bonding potential of the board manufactured at all the Units. Right from the former, press section etc., main production facility is having total 49 dryers, which are arranged in sequence of 23 pre-dryers followed by MG followed by 26 post dryers. After drying, the board is passed from the latest blade coating section, where extremely good quality of coating and gloss is obtained on the board. After that, board is passed on to the parent reel through the latest calendaring system.