From packaging innovation to production efficiency

A concrete example of this philosophy can be seen in the evolution of the AC50 S6 wrapping machine, where MacDue has introduced a solution that allows a reduction in plastic film consumption by 20% to 30% for each wrapped roll. 

The innovation addresses two critical aspects of continuous side-sealing technology: the amount of film needed on the roll heads and the excess traditionally present on the product diameter.
“We have achieved a result comparable to wrapper technology, practically zero on the entire roll diameter, while maintaining all the advantages of heat shrinking,” explains MacDue CEO Fiorenzo Donetti.

The result is not only a reduction in material costs but also an improvement in the environmental impact of the production process. For companies seeking to meet their stakeholders’ sustainability demands, the ability to reduce waste of environmentally harmful materials is becoming an increasingly important factor. For lines operating 24 hours a day at rates of 60 – 80 rolls per minute, this saving translates into a significantly faster return on investment, demonstrating how technological innovation can transform operating costs into lasting competitive advantages.

MacDue’s strategic approach is also reflected in the new Vision System, which represents a tangible improvement in quality control of products arriving at the packaging line. This new technology provides three-dimensional control that monitors external diameter, internal diameter and product flatness. Through the operator panel, it is possible to define the parameters that determine whether to discard a product and to verify the last 20 readings to identify the most common defects.

The system is not limited to quality control but also functions as a predictive analysis tool: it can define a maximum number of consecutive discards and, once that limit is reached, automatically stop the line to allow for upstream verification.

This functionality transforms quality control from a simple final filter into a monitoring system for the efficiency of the entire production line. When the Vision System detects recurring defect patterns, it provides valuable information for optimizing upstream processes, from converting to embossing.

The completion of this systemic vision is achieved in the palletizing phase, where MacDue has invested in the development of highly customized anthropomorphic robotic islands. The distinctive element of these solutions lies in the proprietary grippers, internally designed to handle even the most delicate products with precision. Palletizing often represents the bottleneck of high-speed lines, but MacDue solutions transform this critical phase into a competitive advantage. Synchronized robots guarantee both speed and product protection, while custom design ensures perfect integration with existing lines without compromising productivity.

Each line is designed through a co-design process with the customer, in which specific needs are translated into optimized technical solutions. 

Design flexibility makes it possible to maintain zero format parts even in the most advanced configurations, enabling rapid changes from single to double rolls or between different diameters, without compromising operational efficiency.

Production needs vary from one nation to another and effectively supporting companies in the tissue sector requires understanding their production challenges and packaging needs in order to ensure success. Adapting machines and packaging lines to the peculiarities of local markets is both a stimulating challenge and a natural consequence of the international expansion that MacDue has achieved in recent years.

MacDue’s experience demonstrates that packaging innovation can no longer be considered a secondary element of the production line. 

The technologies developed by the company show how strategic investments in the final phases of the process can generate benefits that extend throughout the entire production chain: from reducing operating costs to improving quality, from environmental sustainability to optimizing production times. These benefits satisfy both the companies that implement them and the stakeholders who demand ever greater efficiency without compromising the green positioning of the entire production and supply chain. In an increasingly competitive market, this systemic vision represents the key to transforming the challenges of the tissue sector into opportunities for sustainable growth and technological differentiation.