Packaging of products is unavoidable as it is necessary to keep the products safe and to carry them easily during their transport and distribution. The paper packaging products are an important part of the overall packaging industry in India. The growth in the Indian paper packaging industry has been largely driven by the enhanced demand for transportation and distribution of several products. Generally, the paper used in the corrugation industry is the recycled kraft paper, while the virgin paper is used in food packaging where food comes in direct contact with the carton or paper. As some kind of packaging is unavoidable, it is expected to be of low environmental impact as well as low cost for both environmental and economic benefits. This study is dedicated to assess the environmental impact of the manufacture of different types of paper packaging corrugated sheets and boxes (two ply, three ply, five ply and seven ply) in terms of Ecological Footprint (EF) as well as to suggest economically viable measures for its reduction through energy efficiency improvements. This study was carried out for an existing packaging industry M/S Vishal Packaging located at Khamgaon, Maharashtra, India. A detailed survey of the industry was carried out for relevant data collection in order to evaluate the associated EF of the corrugated sheets and boxes being produced. This study also suggests some sustainable measures that have the potential to reduce EF as well as production costs for the industry. The EF of two ply, three ply, five ply, and seven ply sheet boxes have been estimated as 0.515, 0.537, 0.527 and 0.524 gha/ton, respectively, for the existing mode. In this study, three different modes of sustainable measures for EF reduction were examined: (1) grid-connected solar PV system for all energy needs, (2) LPG fuelled corrugation heater with conventional grid electricity for other energy needs and (3) LPG fuelled corrugation heater with grid-connected solar PV system for other energy needs. By adopting such measures, the potential reduction in EF for Mode 1, Mode 2, and Mode 3 was estimated at approximately 12.42%, 6.25%, and 11.13% of the total EF, respectively. The EF of raw materials for existing mode and the three energy modes are 88.2% (existing mode), 96.99% (Mode 1), 92.59% (Mode 2) and 96.04% (Mode 3) of the total EF. The investment required for the above three modes was also examined and economic payback period for Mode 1, Mode 2, and Mode 3 was evaluated as 5.3 years, 1.2 years, and 4.3 years, respectively.
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