Futura and Plusline: a unified vision for the future of tissue converting and packaging

The goal was clear: to offer customers a 360-degree solution, combining excellence in converting and in packaging.  At the helm of this strategic union is Guido Dellagnelo, CEO of both companies. With an in-depth experience acquired in Brazil, where he was President of Perini Brazil for several years, Dellagnelo introduced a new and assertive strategy. His vision is perfectly aligned with the philosophy of Fabio Perini, the tissue converting innovator, by focusing on top-of-the-range, high-performance and highly automated machines capable of meeting the changing demands of the global market.
The expansion of Plusline at international level is one of the group’s most ambitious goals.

Plusline: from an idea to Italian excellence in packaging

Acquired in 2020 under the visionary guidance of Fabio Perini, Plusline Srl is a company belonging to the Futura Group specializing in advanced toilet roll and kitchen towel packaging solutions. Its path to growth is closely linked to Christian Zagnoni, CTO of Plusline, a professional with 40 years’ experience in the field of packaging.

Zagnoni says that it all started with a “simple blank sheet” and the team developed 15 different machine models. This focused approach allowed responding to the different product and market demands in a flexible way, following Fabio Perini’s example of innovation. And so technologically advanced machines were born – sturdy machinery capable of producing an extremely high-quality finished product. The company soon established itself as a new and competitive player in the field of packaging, thanks to the creation of a specialized team of about twenty technicians, dedicated to support and line optimization.
An impressive figure is that six years after the installation of the first machine, Plusline can already boast 80 machines installed throughout the world.

The first machine, Together, was conceived for the future, to guarantee total integration in converting lines. Several key factors distinguish these machines from the competition:

• Ergonomics and design: Plusline machines, wrappers in particular, are more ergonomic and compact, with reduced cycles for product processing and larger and more accessible internal spaces.
• Optimized layout: Complete solutions are about 22 meters long, a significantly shorter layout compared to market standards, resulting in a compact and integrated system for customers.
• High-level performance: Casepack is a perfect example of this philosophy. It runs at a speed of about 40 packs per minute, two or three times faster compared to the competition and features smaller dimensions.

The strategy for North America: wrappers and case packers

One of the most challenging goals for Plusline is expansion in the North American market. To achieve this aim, the company has focused on two foundational technologies: the wrapper and the case packer. Initially developed for the companies of the group, these machines have quickly attracted the attention of large multinationals, who have recognized the potential in terms of ROI.

• The wrapper: This machine, highly reliable both for toilet rolls and kitchen towels, has already been installed on almost 40 lines. It is important to highlight that its integration up to palletizing also works on other converting lines.
• The case packer: It represents a strategic Plusline investment for the North American market. Its role is to open, fill and seal the packs. The machine offers superior or equivalent performance compared to market leaders, supported by proven reliability and by a specialized technical assistance service available 24/7.

The importance of these technologies is crucial to the company’s growth, especially in light of the increased production volumes recorded over the past year.

Production and strategic expansion

To support this growth and expand into new markets, Plusline has reached two important milestones: the opening of new facilities. The historic headquarters and the innovation center remain in Bologna, where research, development and prototyping take place. However, the opening of a new production facility in Lucca, in the heart of the paper district, was a foundational step for production, testing and logistics.

And even more strategic was the opening of the Green Bay, Wisconsin, facility, in the heart of the North American tissue industry. More than as a production plant, this new hub was conceived as a showroom to welcome customers, offer post-sales assistance and manage spare parts. Its opening was decisive for Plusline, laying the groundwork for entering the U.S. market and turning the challenge of market penetration into a winning reality.

Today, FUTURA and PLUSLINE are ready to meet any market demand, broadening their customer portfolio on a global level and promoting Italian innovation and excellence. Their success demonstrates the validity of Cavaliere Perini’s philosophy: “An invention must be total, extreme and simple at the same time”.