Tag Archive for: Tecnology

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.

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.

Sipack Boosts Production for Leading Cardboard Company with Royal CE

Sipack has successfully installed a Royal counter-ejector featuring top-loading at
a leading international company, a recognized leader in the corrugated cardboard sector.
The CE Royal was implemented as an upgrade on an existing flexo folder gluer of another manufacturer.
The top-loading counter-ejector fully meets the production requirements of the line. It delivers an
optimized production workflow and increased speed, effectively eliminating machine downtime.

With the integration of the CE Royal, the production line has been optimized, boosting capacity from 15 to
18 BPH and achieving a significant improvement in efficiency and operational continuity.

Simone Cini, Sales Manager at Sipack, comments: “We are proud to have contributed to enhancing their
production process and thank our customer for the trust placed in our technology and our team.”

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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.

 

Mauro Benedetti Spa chooses Sipack’s Royal Flexo Printer

During the interview with Francesca Benedetti

Shortly after the beginning of the interview with Dr. Francesca Benedetti, a message from her production manager arrived on her mobile phone with the words:“Printing test ok!”. We had recently introduced the topic of the interview “Why choose Sipack” and in that message the confirmation of what she was saying “we chose the company, the engineering skill of Walter Pacioni and the real Made in Italy”. Sipack and Mauro Benedetti are both family companies, managed by people with a real passion for corrugated board. The day of the interview, Walter Pacioni, was at Benedetti’s plant to verify the Factory Acceptance Test of the Sipack Royal VB DD Flexographic Printer, during this important event there were not only the testing technicians but also CEO of the company, the one who first drives the company with passion, and success for more than 25 years now. Factory Acteptance Tests are a real challenge and the place around the machine becomes a haven of different colors, various types of cardboard and then… ready to rock and roll: the counting of the lines, the machine speed, the verification of how the letters are written, the logotypes, the images, the cliché, until… to the achievement the desired results and to the words “printing test ok!”.
ZDue, a company specialized in flexo cliché from Modena, and its technicians were also there to support the verification of the machine performance test.
Mauro Benedetti SpA a life dedicated to corrugated cardboard

The history of Mauro Benedetti company is very ancient, the family has always been in the packaging sector, first as coopers, then with wooden packaging and thanks to Francesca’s father, Mauro Benedetti, during his study trip on cardboard in Israel, he introduced this type of packaging to the family business. From that moment the production moved to Perugia, working mainly for a well-known company in the food sector, and only with corrugated cardboard packaging over the years, especially between the ‘70s and ‘80s, the expansion of production plants both in south and in north of Italy, to get closer to its customers, but with the death of his father in 2010, the company wanted to reshape the approach of business, returning to production concentrated on the primary site of Perugia, where they estimate to produce 90 million m2 of cardboard for this 2022. In the last two years we have never stopped the production” continues Francesca Benedetti, “food has been a growth sector, some non food companies have suffered a setback, but we have different type of customers and for this reason the plant was running all the time”. “We have a various range of products: american boxes, die-cut products and also fitments and accessoriesin corrugated board”. We are living through years of transformation, with radical changes: consumer behaviors have changed, the choice of healthy foods, attention to the environment, plastic free packaging, but also the creation of more comfortable home environments with energy saving, e-commerce and the development of family entertainment, a return to the essentials: a new lifestyle… Many companies have undertaken new challenges, in Italy, thanks to economical and financing systems, companies have been facilitated to reinvest in their production sites, with new machinery and services. This has also happened to Mauro Benedetti; infact the company has chosen to make changes to its production with the purchase of high-performance machinery such as the Sipack’s flexographic printer.

The Royal VBDD 12.21 Flexo Printing Machine by Mauro Benedetti

The SipackRoyal VB DD 12.21 flexographic printer installed at the Benedet- ti’s plant is composed by five printing units with vacuum transport from the feeder till to the exit of the sheet, with preparation for the installation of UV dryers on each printing unit, for istant color drying, provided with a transfer unit, but above all with direct drive servomotors on each axis, to ensure maximum accuracy and economy in consumption.

The Sipack Royal VB DD printer is a flexible machine, upgradable over time and suitable for optimizing changeover times; in fact, with this machine it is not required to change anilox rolls depending on the board used, an important aspect for the production: less downtime, less components to be replaced and less maintenance and labour. The fully controlled inking system and the automatic wash up allows the highest print quality and the minimum waste of ink and water, in short, a machine that takes care not only to the quality of the finished product but also to the use of various board types.

The printer is in line with a flatbed die-cutter and is part of Mauro Benedetti SpA’s corporate improvement strategy, along with other machinery recently purchased to respond to changing market demands.

The Future

“Business today means skillfully juggling between an increasingly changing demand but above all being good administrators, with the increase in the costs of raw materials, energy… the stabilition of the price requires few more months, I understand well the situation, because in the company I also supervise costs and purchasing,but I also think that the future is to drive green economy policies”, concludes Francesca Benedetti”.

Scatolificio Laurini: a growing company

ONEDRIVE series by SIPACK at service of production flexibility

 

Scatolificio Laurini’s history is imbued with passion and more than 50 years in corrugated packaging; today it is under the management of Riccardo Sbaraini, a young and brilliant entrepreneur, from technician to CEO since 2013.“I remember when I started working, as punishment from my mother!” recounts Sbaraini. “I had interrupted my studies and she thought that working for some months in a company and making boxes would make me change ideas about school.” .
 
The CEO started his career from the bottom, gaining professional experience – at first as a technician, then as production manager, until the day he became aware that he could manage the company, together with a winning team of colleagues. Today, the company is a reference point in the Northern Italy for many customers that require complex packaging for specific types of products.
 
An investment to support the thriving local company
In 2021, the company felt the need to make a step forward, increasing productivity and quality with the purchase of a new Sipack’s machine: a printer slotter ONEDRIVE 1272×3100. 
From a recent study carried out by Brescia’s Confindustria, related to the first quarter of 2021, the territory has grown of more 4.8% compared to the previous quarter.
“Understanding the trend of the local market and interpreting the changes of the last year have been essential to guide important business choices and looking ahead; finally learning that my customers are experiencing a period of growth, it gives me confidence for the future,” continues Sbaraini.
This growth has encouraged Sbaraini in the choice of a machine with high quality and quantitative standards, which was simple in use and automatic, using the latest technology.
“It is clear that the market requires more flexibility than just few years ago,” adds Sbaraini. “The word ‘flexibility’ has become a ‘mantra’ of industry insiders: for last-minute orders, the procurement of raw materials and for production management. In addition to this scenario, also the request of all types of packaging,with different quantities, from few pieces to large lots. 
“Thinking about all these variables, the choice was quite simple. I needed a flexible, fast and automatic machine that would saved us on production time, maintenance and consumption.” adds Riccardo Sbaraini
 
Sipack’s ONEDRIVE printer slotter in detail
Sipack, an Italian company with 25 years of corrugated converting machinery experience, responds to the requests of companies such as Scatolificio Laurini, who need high performance, flexible machinery that guarantees excellent quality of the finished product. The Printer Slotter ONE DRIVE has been developed for these kind of needs. It is flexible in formats, fast in product changeover times, but above all, it allows users to reduce costs, especially as it is considered a low power consumption machine. Thanks to the lead edge feeder, the first production process is guaranteed, even with low quality and warped sheets; the top printing units are easy to handle and guarantee good flexo printing quality. 
A motor on each unit combines the precision of direct-drive technology with its application simplicity, and the machine’s maintenance is significantly reduced; less maintenance parts, being life sealed and lubricated components, and there are no oil leaks. 
The slotter, with four pairs of shafts, is equipped with an intelligent system for cutting heads moving. It shifts the knives smoothly, in order to manage the different formats and ensure high performance.
The further advantage of SIPACK’s technology is visible: after years of production, the machines looks new as the first day of production due to less wear of mechanical parts. The machinery remains intact and durable in time and if combined to a special scheduled service packages, the longevity of the machine is even doubled.
“We’ll have years of intense work, but I am aware that thanks to this new machine, I will improve production and it will make easier life for my operators in order to meet customers’ demands,” concludes Sbaraini.