The Stages of Our Production Process.
This section provides a chronological overview of our working methodology.
The main macro-stages encompass packaging design, cutting die production, and accessories preparation.
1 Design & Pre-press Services
Analysis, Problem-Solving and Packaging Design
Based on the product to be packaged and the client’s specific requirements, a bespoke packaging concept is developed and engineered, offering a range of structural solutions designed to enhance the presentation and protect the contents.
Prototyping
Production of the technical drawing and physical plotter sampling, with the option of creating custom mock-ups to test the structural integrity of the design prior to full production.
Ink-Free Areas (Varnish Reserve)
Manufacture of custom-shaped plates tailored to the client’s machinery, designed to mask the areas of the packaging intended for gluing or coding, keeping them free from varnish or coating.
2 Cutting Die Production
Technical Die Drawing
Supply of the technical die drawing by the client, or in-house production by our dedicated technical department.
Laser Cutting
Cutting stage using CO₂ laser technology to define cutting zones and intricate die details with maximum precision.
Blade Mounting
Mounting of cutting blades, selected according to the thickness and type of material being processed. Available configurations include: centre bevel, side bevel, single bevel, and double bevel.
Creasing Rule Mounting
Mounting of creasing rules to ensure accurate folding of carton blanks, calibrated to the thickness and type of material selected.
Rubber Ejection (Stripping Rubber)
Cutting and application of ejection rubber to facilitate the stripping of the board after die-cutting, calibrated specifically to the type of board being used.
3 Accessories Preparation
Ejection Systems (Strippers)
Application of waste-removal accessories with the installation of upper and lower ejectors — available in traditional, dynamic and strip-clip-system variants — to facilitate the automatic ejection of waste slugs in die-cutting machinery, optimising throughput relative to the complexity of the die layout.
Counter-Dies (Counter-Plates)
Production of essential supports designed to guide and assist the accurate folding of packaging blanks, selected and calibrated specifically to the type and thickness of the material used.
Milled Counter-Plates
High-precision advanced supports engineered to optimise the creasing of packaging in the paper and board converting industry. CNC milling from solid stock guarantees hundredth-of-a-millimetre tolerances, drastically reducing machine make-ready time and ensuring consistent, perfect folding even across long print runs.
Embossing and Hot Foil Stamping
Integration into the cutting die of dedicated clichés and stamping dies for packaging enhancement, custom-engineered to produce three-dimensional embossed effects or specific surface finishes on the finished product.
Braille and Accubraille
In-house production of dedicated matrices and punches for the impression of tactile writing systems on packaging, ensuring maximum legibility and full compliance with accessibility and safety requirements. For the Accubraille system, universal and bespoke supports are developed, designed to guarantee complete compatibility with any die-cutting machinery or folder-gluer in use at the client’s site.
Layout Separators (Stripping Frames)
Layout separators — available in traditional or quick-frame configurations, in both upper and lower versions — are designed to optimise the separation and discharge of individual packaging blanks after die-cutting. Their combined action ensures perfect blank detachment and maximum throughput efficiency in industrial automation processes.
Quick-Frame Systems
For the Quick-Frame system, universal bespoke supports are developed and adapted to the machinery in use at the client’s facility.
4 Quality Control and Delivery Logistics
Inspection and Compliance Verification
Before packaging, every cutting die undergoes rigorous testing with high-precision instruments to verify full conformity with the technical drawing, eliminating the risk of defects and non-conformities.
Secure Packaging and Storage
Once quality checks are passed, products are protected with purpose-specific packaging to preserve the integrity of blades and components, labelled for full traceability, and stored in the dispatch area.
Direct Delivery with Own Fleet
Shipping is managed in-house using our own fleet of vehicles: a dedicated logistics operation that eliminates the risk of damage associated with conventional couriers and guarantees flexible, secure and punctual deliveries.