The Ultimate Guide to Duplex Board: Definition, Types & Top Brands
Everything a printer or packaging expert needs to know about Duplex Paper Board. From understanding GSM and coating levels to choosing the right manufacturer for your offset press.
1. What is Duplex Board?
Duplex board is a type of paperboard or cardboard widely used in the packaging industry. As the name "Duplex" implies, it is a multi-layered board containing two distinct surfaces: a coated, glossy top surface for superior printability, and a stronger, rougher back layer (usually grey or white) for structural support.
Unlike simple kraft paper, Duplex Board is engineered for stiffness. It is the backbone of the global packaging industry, used to create boxes for everything from pharmaceuticals and cosmetics to shoe boxes and garment tags. It is technically referred to as Coated Recycled Board (CRB) because it is predominantly manufactured using recycled paper pulp, making it an eco-friendly choice.
Key Characteristics:
- GSM Range: Typically 230 GSM to 450 GSM.
- Stiffness: High rigidity to withstand stacking pressure.
- Surface: One side Coated (glossy) for offset/gravure printing.
The Manufacturing Process
To understand the quality of a board, you must understand its layers. A standard high-quality board like Khanna Duplex is composed of three to four layers:
- Top Coating: A blend of China Clay (Kaolin) and Calcium Carbonate. This layer determines the whiteness, smoothness, and ink absorption.
- Top Liner: Made from bleached virgin pulp or high-grade recycled office waste. This provides the white background for the coating.
- Middle Ply (Filler): The thickest part of the board, made from mixed waste paper (old newspapers, cartons). This gives the board its "Bulk" and thickness.
- Back Liner: The bottom layer. If it's grey newsprint pulp, it becomes "Grey Back". If it's bleached pulp, it becomes "White Back".
Why is it the #1 Choice for Packaging?
Duplex board strikes the perfect balance between cost and performance. While Virgin Packaging Board (FBB) is stronger, it is significantly more expensive. Duplex board offers 80% of the strength at 60% of the cost, making it the standard for High Volume Low Cost (HVLC) packaging like FMCG, Matches, and Agarbatti boxes.
2. Types of Duplex Board / Packaging Board
Not all boards are created equal. In the Delhi market, you will primarily encounter four main categories. Knowing the difference can save you thousands of rupees in printing errors.
LWC vs. HWC Duplex
The coating weight is the primary differentiator here.
| Type | Full Form | Best Used For |
|---|---|---|
| LWC | Light Weight Coated | Low-cost jobs, simple 2-color printing, inner liners. Lower gloss. |
| HWC | High Weight Coated | Premium multi-color offset printing. High gloss, smooth finish (e.g., Khanna Optic). |
Grey Back vs. White Back
Grey Back Duplex Board: The most common type. The back is grey (recycled newsprint look). It is opaque and tough.
Usage: Shoe boxes, cereal boxes, corrugated outer liners.
White Back Duplex Board: The back is white (bleached pulp). It looks cleaner and more hygienic.
Usage: Pharma boxes, cosmetic cartons, food packaging where the inside must look clean.
3. Top 5 Main Companies in India
India is a global hub for paper manufacturing. Here are the top 5 giants dominating the Duplex Board market, ranked by a mix of quality, availability in Delhi, and value.
Khanna Paper Mills (KPM)
Why it is the Best Choice:
Khanna Paper Mills, located in Amritsar, is the largest single-location paper mill in India using recycled fibre. For printers in Delhi NCR, Khanna is the Gold Standard.
- Best Bulk: Their "Diamond" series offers stiffness comparable to FBB at a fraction of the price.
- Availability: Being close to Delhi, supply is consistent (unlike mills in South India).
- Range:
- Optic (Grey Back): The market leader for general packaging.
- Alfa (White Back): Premium clean-look board.
- Diamond: Heavy-duty stiffness.
2. Century Pulp & Paper
A division of the Birla Group, Century is synonymous with quality. Their manufacturing plant in Lalkua (Uttarakhand) produces excellent board.
Pros: Extremely consistent shade. Cons: Often priced at a premium compared to others.
3. ITC Bhadrachalam
The giant of the industry. While famous for their virgin boards (Cyber XLPac), their recycled "Eco" range is also widely used.
Pros: Top-tier technology. Cons: Focus is heavily on virgin boards; recycled availability can fluctuate.
4. NR Agarwal Industries (NRAIL)
Based in Gujarat (Vapi), NRAIL is a massive player in the duplex segment. Their "NRAIL Coated" boards are very popular in Western India and have a strong presence in Delhi.
Pros: Good gloss levels. Cons: Transport time to Delhi is longer than Khanna.
5. Emami Paper Mills
Famous for newsprint, Emami also produces high-grade packaging board from their Balasore plant. Their "Glamkot" brand is well-respected.
Pros: High brightness. Cons: More dominant in Eastern India markets.
| Company | Top Brand | Best For | Rating |
|---|---|---|---|
| Khanna Paper | Optic / Diamond | Overall Value & Stiffness | ★★★★★ |
| Century | Zorrik | Premium Surface | ★★★★☆ |
| ITC | Eco Blanca | Brand Consistency | ★★★★☆ |
Frequently Asked Questions
What is the standard size of Duplex Board? +
Common sizes are 25"x30", 30"x40", and 22"x28". However, at Krishna Trading Co., we offer reel-to-sheet cutting to give you any custom size you need.
Is Duplex Board waterproof? +
No, standard duplex board is paper-based and not waterproof. However, it can be laminated with BOPP film after printing to make it water-resistant.
Why is Khanna Board preferred in Delhi? +
Due to the proximity of the mill (Amritsar) to Delhi, the board is fresher, suffers less transport damage, and is available at better rates compared to southern mills.