A success story: Megabox Srl

1. The Company

Megabox is an Italian group active in the cardboard packaging sector for over 50 years and is today one of the leading companies at a national level.

The group includes:

  • Ondulati del Savio – Transformation of paper and rolls into corrugated cardboard
  • Inpack – Production of protective cardboard solutions
  • Megabox – Box factory based in Montecchio (PU)

Thanks to an integrated supply chain, the company ensures production flexibility and Just-in-Time services, even in a scenario of rising raw material costs.

2. The Challenge

Megabox needed to replace its existing casemaker with a higher-performing solution capable of:

  • Being technologically cutting-edge
  • Improving precision, efficiency, and production reliability
  • Optimizing energy consumption and material usage (e.g., glue)
  • Reducing changeover times
  • Ensuring high quality standards with increased automation

The goal was not only to upgrade a machine, but to achieve a qualitative leap aligned with the company’s vision of continuous improvement.

3. The Solution

The choice fell on the Royal VB DD casemaker, which stands out for:

  • Direct drive motors on every axis
  • Siemens automation systems and Motion System Control with energy regeneration
  • Automated format change manageable by a single operator
  • Robot slotter for automatic positioning of cutting heads
  • Intelligent HMI for quick parameter setup
  • High-pressure ERO gluing system
  • Vacuum transport and pneumatic wheel closing

4. The Result

Four years after installation, the line has delivered:

  • Higher production efficiency
  • Faster format changeovers
  • Improved quality and precision
  • Reduced energy consumption and material waste

Statement

“The Royal VB DD has enhanced our production performance, ensuring care and precision at every stage of the process. A technological choice fully in line with our growth path.”
— Ivano Angeli, President of Megabox Srl

Direct Drive Technology in Flexo Folder Gluers: Enhanced Efficiency and Control in Corrugated Board Converting

In the corrugated cardboard converting industry, the adoption of increasingly advanced drive technologies has become a key factor in improving machine performance, process stability, and overall equipment effectiveness (OEE). Among these, independent motorization based on Direct Drive technology is gaining significant traction. This approach uses a dedicated motor for each axis or functional unit of the machine—typically a brushless motor—directly coupled to the driven component, without intermediate transmission elements such as belts or gears.

1. Independent Motorization and Direct Drive Explained

Direct Drive motorization is based on a simple yet highly effective concept: eliminating mechanical transmission components (belts, pulleys, gears) between the motor and the working axis, and connecting the motor directly to the moving part. This design minimizes power losses, friction, mechanical backlash, and wear-related components.

Direct Drive systems are usually implemented with brushless motors (servo or brushless DC) combined with advanced electronic control systems that precisely regulate speed and torque.

In corrugated box production machinery, this translates into extremely accurate control of all critical movements along the line—such as sheet handling, folding and gluing operations, and final conveying—resulting in higher operating speeds, improved synchronization, and consistently superior product quality.

2. Technical Advantages of Direct Drive in Corrugated Machinery

Reduced Noise and Vibration
The absence of mechanical transmission systems leads to a substantial reduction in noise and vibration during operation. Vibrations typical of belt- or gear-driven systems—often caused by backlash and mechanical compliance in the transmission elements—are virtually eliminated. As a result, the machine operates more quietly and remains more stable under load, an important advantage in high-speed production environments and multi-shift operations.

Lower Friction and Improved Energy Efficiency

With the motor directly coupled to the driven axis, there are no intermediate components dissipating energy through friction. This results in higher overall drive efficiency and improved energy performance, with potential reductions in electrical consumption and operating costs.

Higher Precision and Faster Dynamic Response

Electronic control of Direct Drive motors allows for extremely fast and accurate speed changes. This capability is particularly beneficial during fine positioning tasks, sheet alignment, and multi-axis synchronization, where system responsiveness directly impacts the final quality of the finished boxes.

Reduced Maintenance and Increased Reliability

Fewer moving mechanical parts mean reduced wear and significantly lower maintenance requirements. Belts and gears do not require replacement, lubrication, or periodic adjustment, simplifying scheduled maintenance and minimizing unplanned downtime—key factors in maximizing machine availability.

3. Why Direct Drive Matters in Corrugated Box Production

In corrugated production lines, productivity and reliability are critical performance indicators: every machine stoppage or quality deviation translates into tangible costs for the converter.

Direct Drive technology helps to:

  • Improve process smoothness through precise synchronization of multiple independent motors, enhancing cutting, folding, and sheet transport accuracy.
  • Reduce the risk of positioning errors, especially during short runs or frequent job and format changes.
  • Enable higher levels of automation and electronic control, seamlessly integrated with modern digital supervision, monitoring, and diagnostic systems.

4. Conclusion: Tangible Value for the End Usern

For corrugated cardboard converters, Direct Drive technology and independent motorization represent a concrete lever for improving efficiency, quality, and competitiveness. Reducing mechanical friction and noise is not only an operational benefit—it leads directly to higher production accuracy, lower maintenance costs, and greater operational flexibility, particularly in environments characterized by frequent format changes and variable production requirements.

In the design of its corrugated cardboard machines, SIPACK integrates these principles to deliver robust and reliable solutions that maximize production efficiency and overall customer performance. Direct Drive is therefore not just a trend driven by market leaders, but a proven technology that delivers real, measurable advantages in everyday production environments.