The proprietary technologies developed by MacDue in recent years demonstrate how targeted investments in the final phases of the process can generate significant benefits for the overall efficiency of the line.
A concrete example of this philosophy can be found in the evolution of the AC50 S6 wrapping machine, where MacDue developed a solution that allows for a reduction in plastic film consumption from 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 aiming to meet their stakeholders’ sustainability demands, the ability to minimize waste of environmentally harmful materials becomes an increasingly relevant aspect.
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 the quality control of products arriving at the packaging line.
While traditional systems were limited to a two-dimensional photograph of the surface, the new technology offers three-dimensional control that monitors external diameter, internal diameter, and product flatness. Through the operator panel, parameters can be defined to determine whether to discard a product and verify the last 20 readings to identify the most common defects.
The system is not limited to quality control but becomes a predictive analysis tool: it can define a maximum number of consecutive discards and, if 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 realized in palletizing solutions, where MacDue has invested in developing 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’s solutions transform this critical phase into a competitive advantage.
Synchronized robots guarantee speed and product protection, while custom design allows perfect integration with existing lines without compromising productivity.
What distinguishes MacDue’s approach is the ability to integrate these innovations into completely customized solutions. Each line is designed through a co-design process with the customer, where listening to specific needs translates into optimized technical solutions.
Design flexibility allows for maintaining 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.
Particular attention is paid to the evolution of international markets. Production needs change from one country to another and effectively serving companies operating in the tissue sector means understanding the production challenges they face and the packaging needs they must meet to succeed.
Adapting machines and packaging lines to the peculiarities of local markets is both a stimulating challenge and a natural consequence of the international expansion MacDue has experienced in recent years. MacDue’s experience demonstrates that packaging innovation can no longer be considered an accessory 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 propagate throughout the entire production chain: from reducing operating costs to improving quality, from environmental sustainability to optimizing production times.
These benefits meet the needs of both the company leveraging 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 tissue sector challenges into opportunities for sustainable growth and technological differentiation.
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