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How to Start Air Bubble Sheet Manufacturing Business?

Business setup

How to Start Air Bubble Sheet Manufacturing Business?

07 Jun, 2023
Air Bubble Sheet Manufacturing

Air Bubble Sheet Manufacturing Business, also called bubble sheets, are plastic sheets containing tiny air-filled bubbles. They provide superior protection against scratches compared to paper and are commonly utilized for safeguarding items during shipping and storage. Air bubble sheets are extensively used for packing various products, including electronics, electrical goods, glassware, delicate collectables, expensive household items, and machinery. These sheets serve the purpose of keeping the goods well-protected, ensuring their safe transport and storage. With the growing popularity and increased interest in online shopping in urban areas, the usage of air bubble sheets has expanded across a wide range of businesses, from small shops to large companies. The demand for air bubble sheets is on the rise as they offer effective cushioning and protection for delicate items during transportation.

Air Bubble Sheet Manufacturing Business

The process to start an Air Bubble Sheet Manufacturing Business


Generally, the startup cost for an air bubble sheet manufacturing business can range from approximately 5 lakhs to 50 lakhs Indian rupees or even higher for larger-scale operations. This cost encompasses various factors, including machinery, raw materials, labour, and marketing expenses. The specific investment required may vary based on the scale of the operation and the desired production capacity.

License and Registration

To start a manufacturing unit for air bubble sheets, acquiring a license from the state government and applying for GST registration[1] is essential. The production process of air bubble sheets ordinarily does not generate harmful waste. However, it is necessary to obtain a no-objection certificate from the state pollution control board (NOC from SPCB) as a precautionary measure. Additionally, registering a trademark can help protect your brand name and establish its uniqueness in the market.

Space for business

For an Air Bubble Sheet Manufacturing Business having a small-scale operation, it is feasible to set up the manufacturing unit in a space ranging from 500 to 1000 square feet. However, if you intend to establish a medium-sized operation, you may require a space of approximately 1500 to 2000 square feet. On the other hand, a large-scale operation may need an area of 5000 square feet or more. It is crucial to consider various factors, such as storage space for raw materials and finished products and office space requirements. Proper space allocation is essential to ensure smooth operations and efficient management of the manufacturing unit.

Raw materials

The primary raw materials used to produce bubble sheets for this business are low-density polyethylene, masterbatch for colouration, and air retention agents.

Required machines

You will require a bubble sheet-making machine to establish a bubble sheet-making business. Other essential equipment includes an extruder machine, a bubble-forming machine, a slitting machine, and cooling fans for water tanks. These machines and equipment are crucial for producing and processing bubble sheets.

Manufacturing process

The Air Bubble Sheet Manufacturing Business involves several steps. First, the granules of low-density Polyethylene (LDPE) are placed into the hopper of an extruder. These granules are then melted and transformed into plastic as they pass through the extruder under pressure. The melted plastic is directed toward the die, which is shaped into rings forming the bubble sheet. The thickness of the LDPE layers is adjusted, and both layers are formed simultaneously in the die.

Next, the air bubbles are thermoformed within the LDPE layers, and as the pressure is applied in the second layer, the air bubbles become laminated. Following this, other processes, such as lamination and cooling of the outer surface, are carried out simultaneously using rulers. Once the bubble sheet is fully prepared, it undergoes cooling using chillers and is then arranged and wound onto a winder for further processing.

Marketing for business

To begin with, the marketing for your Air Bubble Sheet manufacturing business, reach out to E-commerce companies in your locality and provide them with details about your business. Inform them about your products, including electronic items like mobile phones, locks, mixers, and more. Additionally, you can establish connections with manufacturing companies producing toys, utensils, medicine, ceramic clay items, and showpieces. Collaborating with these companies allows you to take orders in bulk. Promoting your business in the local newspaper is another effective strategy.

Furthermore, leveraging online platforms such as social media sites can significantly enhance your reach. Share information about your business on these platforms to generate awareness and attract potential customers. In this regard, consider seeking assistance from marketing companies to enhance your promotional efforts.

Profit margin

The profitability of this business can vary depending on various factors such as production costs, product demand, market competition, pricing strategy, and distribution channels. Typically, the profit margin in this industry ranges from 10% to 30%. However, achieving a higher profit margin necessitates efficient production processes, cost management, and effective marketing strategies. Additionally, the costs associated with raw materials, labour, and equipment can also impact the overall profit margin of the business.


Research indicates that the global market size for Air Bubble Sheet Manufacturing Business was approximately USD 2.8 billion in 2021, and it is expected to reach USD 3.9 billion by 2023. With the increasing prevalence of e-commerce and online shopping, there is a strong demand for secure and reliable packaging solutions to ensure that products reach customers in optimal condition. This growing market reflects the importance placed on safe and protected packaging in the modern era of retail and logistics. Starting this business requires careful planning, including obtaining the necessary licenses and registrations, securing appropriate space, and acquiring essential machinery and raw materials. The profitability of the business depends on factors such as production costs, market demand, pricing strategy, and efficient operations. It is highly recommended to take expert consultation to obtain NOC from SPCB and other necessary permits and approvals to avoid legal penalties and experience a hassle-free process.

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