1. Raw Material Inspection (Incoming)
Paper Testing: Conduct rigorous testing of Kraft paper rolls for GSM, Bursting Factor (BF), Moisture Content, and COBB values.
Adhesive & Ink Control: Perform Viscosity Testing for starch-based glues and flexographic inks to ensure optimum bonding and print clarity.
Plastic Granules: Inspect incoming plastic resins/sheets for thickness, color consistency, and purity for the thermoforming unit.
Vendor Compliance: Verify Supplier Test Reports (COA) and maintain a "Log Book" for all incoming materials.
2. In-Process Quality Control (IPQC)
First-Piece Approval: Verify the dimensions, flute profile, and printing of the first sample of every new production run before mass production starts.
Line Audits: Conduct hourly floor checks on the 5-ply/3-ply automatic plants to monitor bonding strength and sheet alignment.
Machine Calibration: Ensure that testing equipment (Bursting Strength Tester, Moisture Meters, Vernier Calipers) is calibrated and functioning accurately.
Waste Reduction: Identify and segregate "Non-Conforming" (rejection) material on the shop floor to prevent it from reaching the next stage.
3. Laboratory & Strength Testing
Finished Product Testing: Perform Box Compression Tests (BCT) and Edge Crush Tests (ECT) to ensure the boxes can withstand stacking and transit.
Viscosity Management: Maintain the standard "Seconds" for glue and ink flow using Zahn or Ford Cups, adjusting for temperature variations during the day.
Color Matching: Ensure the printing shades match the approved "Master Sample" or Pantone shades provided by the client.
4. Documentation & Compliance
Report Generation: Prepare Daily Quality Reports (DQR), Rejection Analysis Reports, and Final Inspection Reports.
Standardization: Assist in maintaining documentation for ISO 9001:2015, BRC, or any other Food Safety standards required by VPPL’s clients.
Root Cause Analysis (RCA): In case of a customer complaint, investigate the production batch to find the root cause and suggest corrective actions (CAPA).
5. Final Dispatch Clearance
AQL Sampling: Perform final random sampling (Acceptable Quality Level) before the material is loaded into the truck.
Packaging Check: Ensure proper palletizing, strapping, and labeling to prevent damage during transport.