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.

A new Technical Director for Sipack

Through this interview, we introduce our community to the new Technical Director, Gianluca Giometti, who officially joins the Sipack team. His arrival marks the beginning of a new chapter for the technical area—one driven by development, innovation, and a clear vision for the company’s future, fully aligned with a group-wide corporate culture increasingly focused on synergy and integration.

Your professional journey within the Italia Technology Alliance group has now led you to take on a new role. Which skills you have developed will be most useful in this new experience?

My career serving companies strongly oriented toward automation has been very long. I began my career as an electronics technician, but what has always driven me forward is a constant curiosity for research and innovation. The desire to understand how to best automate processes and develop increasingly efficient, cutting-edge machinery has been the common thread of my growth, with the goal of responding to market challenges with innovative and practical technical solutions.

You are joining SIPACK at a key moment of major relaunch. What are your first priorities as Technical Director?

The current priority at SIPACK is to work on engineering, with the aim of structuring the company and increasing the technological level and, consequently, the range of products and services. It is an important challenge, which I consider one of the main objectives for the coming years.

What kind of Technical Director do you want to be? Where would you like to take the technical area over the next 2–3 years?

My goal is to lead Sipack’s technical area by implementing high-quality technological solutions capable of combining innovative value, operational robustness, and cost sustainability. I believe it is essential that every phase of ideation and design takes real feasibility into account, also through comparison with approaches and solutions from different sectors. To remain competitive, it is necessary to move beyond the established mindset of “we’ve always done it this way,” responding to the market with creativity, flexibility, and innovation.

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Sipack’s Move Forward

A renewed company, driven by product innovation and new market opportunities

Sipack, the Lucca-based company specializing in corrugated cardboard machinery, is entering a new phase of industrial and technological growth, just months after joining the Italia Technology Alliance.

Walter Pacioni, CEO of Sipack, welcomed us into his vision for the company, sharing key insights on the challenges ahead, new goals, and what’s next. Here’s what he had to say.

What changes will current and future customers see following this acquisition?

For both existing and future clients, Sipack’s entry into the Italia Technology Alliance marks a significant step forward — one that stays true to our core identity: combining industrial strength with continuous innovation. The first major benefit is access to a fully integrated ecosystem of expertise, technology, and services. This means we’ll be able to respond faster and more comprehensively to customer needs. In practical terms, this translates into higher-performing lines, integrated systems, greater operational efficiency, and a more seamless customer experience throughout the entire product lifecycle. We’re also enhancing our after-sales service. Thanks to the group’s global technical and commercial network, we can now provide quicker, more structured support on existing installations. Finally, being part of an internationally focused group that still champions Made in Italy opens new doors for our clients. Sipack will be able to support them in even more ambitious projects, ensuring continuity, reliability, and innovation as they enter new and growing markets. To sum up: our identity remains the same, but our horizons are expanding. We’re becoming a more solid, more innovative partner with a clear long-term industrial vision.

What added value does this partnership bring to the local area and the Italian packaging supply chain?

This partnership is a concrete example of how a regional network can work together to strengthen local talent and relaunch Italian excellence in strategic industries like packaging. Sipack has long been a reference point in Italy for the design and production of corrugated cardboard systems. By joining the group, that legacy is not only preserved but reinforced — with expertise, jobs, and investment remaining rooted in the local industrial fabric. On a supply chain level, the alliance enables vertical integration of different fields — mechanics, automation, intralogistics, and digital — into a single Italian tech hub. This makes it possible to offer complete, “Made in Italy” solutions from the heart of the Tissue and Cardboard Valley, capable of competing globally. It reduces reliance on foreign suppliers and boosts national industrial independence. Moreover, shared infrastructure and know-how among Italian companies create beneficial impacts across the entire supply chain, generating opportunities for suppliers, subcontractors, research centers, and local technical training institutions. In short, this move is an investment in the future of Italian packaging — with the goal of building an integrated tech district that can innovate, export value, and train the next generation of professionals.

What signs of growth and development has Sipack already shown recently?
Just months after joining the group, Sipack has demonstrated a clear boost, reaffirming its presence in the Italian market with tangible results. Among the first confirmations is the strengthening of its offering in the converting segment with two leading lines: Royal VB DD, the benchmark model for those seeking top-level performance, and OneDrive, versatile and simple, adaptable to various markets and appealing to those who demand both performance and flexibility, along with smaller machines such as the Royal counter ejector and die-cutting units.

Details on Sipack technology: Royal VB DD and OneDrive
Royal VB DD is Sipack’s high-end flexo folder gluer, fully equipped with direct drive motors on every axis, essential for ensuring precision and reliability during production. Siemens automation systems and Motion System Control, with energy regeneration, allow the line to achieve higher efficiency and process accuracy, reducing consumption while maintaining high production standards.
Royal VB DD features bottom printing and very simple format and/or printing cliché changes, thanks to operational design that enables changeovers with only one line operator. The slotter robot moves the cutting heads smoothly and precisely to any position directly from the panel: the operator inputs the box format data via the HMI, and the machine automatically adjusts to the new format, even for special packaging, die-cut, or printed-only boxes.
The gluing system, equipped with a high-pressure HP electronic gluer, guarantees secure adhesion even at high speeds, significantly saving glue and keeping the machine cleaner. The vacuum transport stabilizes the sheet throughout the line, while toothed belts carry the box through to full closure. The box is perfectly pressed on the sides thanks to pneumatic pressure wheels that prevent reopening, allowing smooth stacking in the Royal Counter Ejector with top loading.
This line has been designed for all box plants that require high-quality machinery with particular attention to operational details.

Also for the OneDrive series, attention to detail is paramount. Available in standard or quick-change (QS) versions, OneDrive is designed for a flexible market. The line includes a Lead Edge feeder, printing units, slotter, rotary die-cutter, fold-gluer, and Royal counter ejector with top loading.
A vacuum transport belt is installed to keep the sheet perfectly stable and registered during the transfer between printing units and in the folding section, one of the most delicate and critical phases for the box. The slotter, with four pairs of shafts—a hallmark of all Sipack machines—is equipped with a cutting-head robot that smoothly and precisely moves the knives to easily handle different formats and ensure high performance, the true highlight of Sipack machinery.
Finally, all Sipack machines can be equipped with a camera system that helps even a single operator monitor the entire line and can be shared for line monitoring and maintenance.

In conclusion
Sipack confirms its role in the corrugated cardboard sector, supported by renewed innovative capacity and an increasingly aligned product range to the needs of an evolving market. With advanced technologies, attention to detail, and a flexible approach, the company supports its customers in reaching new production milestones while maintaining the values of quality, reliability, and service that distinguish it. Sipack’s future is in motion, aiming to be a reference point for Italian and international box makers, focusing on innovation and operational concreteness.