A success story: GADAR S.p.A.

The Company

Founded in 1961 by the Barni brothers, Gadar S.p.A. is a Tuscan box manufacturer that has built its reputation on artisanal quality and a passion for corrugated cardboard. Today, with the third generation already active, Gadar serves diverse sectors such as agri-food, household cleaning, and pharmaceuticals, while maintaining strong family values and attention to detail in every box produced.

The Challenge

With expanding markets and growing demand for quality packaging, Gadar faced new challenges: increasing productivity without compromising the precision and high quality that have always defined the brand, optimising material usage to reduce waste, ensuring consistent printing and die-cutting standards, and meeting the requirements of the agri-food sector, where colour and attention to detail are decisive factors in product sales.

At the same time, Gadar was looking for a reliable and flexible technological solution that could be easily managed by operators and grow alongside the company, ensuring ongoing production continuity and long-term competitiveness.

The Solution

The solution came with the installation of the Royal VB DD rotary die-cutter by Sipack, a Made in Italy machine that combines cutting-edge technology with ease of use.

Thanks to direct drive motors and high-quality components, the Royal VB DD enabled Gadar to achieve precise die-cutting and sharp printing, while reducing material and ink waste.

Fast setup times and an automatic washing system simplified the operators’ work and minimised machine downtime, while the machine’s flexibility and capacity for future upgrades ensured the investment would keep pace with industry innovations.

The Result

Three years after installation:

  • Higher print and die-cutting quality, with more vibrant colours and sharper details.
  • Reduced material and ink waste.
  • Increased productivity, with faster setup times and minimised machine downtime.
  • Lower energy consumption and more efficient material management.

Statement

Sipack’s rotary die-cutter has delivered excellent print quality and cutting precision, improving production efficiency and allowing us to enter a strategic market segment.

It has also demonstrated outstanding performance on coated board, ensuring high graphic definition, uniform coverage, and excellent ink adhesion, even on the most complex jobs.

Barni Family, Gadar S.p.A.

Slotting and Creasing: How the Slotter Makes the Difference

In corrugated box production, even a minor cutting or creasing error can compromise the entire line: misshapen boxes, rising waste, machine downtime. The slotter unit is the station that determines the quality of every fold and cut on the sheet, and it is here that a fundamental part of the converting process takes place.

The Role of the Cutting Heads

The cutting heads work directly on the sheet to perform:

  • vertical and horizontal slots along the panel walls;
  • precise creases and folds without damaging the corrugated fibre;
  • perforations or special cuts according to the box design.

Even a minimal misalignment can cause slippage, irregular folds or deformations, with a negative impact on the subsequent folder-gluer stage. The adoption of robotic and servo-assisted systems, as featured in Sipack machinery, ensures consistent and reliable alignment even on high-speed lines.

Sipack Advanced Technologies

Sipack machinery integrates solutions designed to optimise slotting and creasing:

  • Robotic cutting heads: automatically move into position based on the set format, eliminating manual adjustments and ensuring millimetre-level precision;
  • Servo-motorisation on all axes: guarantees smooth and consistent movement, reducing the risk of sheet deformation;
  • Integrated vacuum transport: keeps the sheet stable throughout its passage through the slotter, eliminating slippage and registration issues;
  • Quick format changeover: transitions between different formats without compromising precision or production continuity.

These features make Sipack systems suitable even for complex boxes with multiple folds or unusual geometries.

Benefits for Quality and Productivity

The technologies integrated into the slotter deliver tangible advantages on two fronts:

Sheet Quality

  • Cuts and slots consistently aligned with millimetre precision;
  • Clean creases, free from fibre fraying or deformation;
  • Uniformity in folding and final box assembly.

Production Efficiency

  • Seamless integration with complete lines: printing, folder-gluer and counter ejector.
  • Reduced setup times thanks to automatic head positioning;
  • Higher production speed with digital motion control;
  • Less waste and fewer machine stoppages thanks to sheet stability and process optimisation;
  • Seamless integration with complete lines: printing, folder-gluer and counter ejector.

Conclusion

Investing in a technologically advanced slotter unit means choosing reliability, repeatability and consistent quality across every format. With Sipack systems, converting companies can reduce inefficiencies, protect the quality of the finished product and respond with greater flexibility to market demands. A competitive advantage that makes itself felt every day, box after box.