In the highly competitive world of corrugated packaging, the pursuit of technical perfection is an ongoing journey. On the one hand, there is the need to preserve the reliability of established printing lines; on the other, the necessity to elevate graphic quality while reducing set up times and waste.
This is the backdrop for the recent and successful partnership between Antonio Sada & Figli Spa and BFT Group. This case study demonstrates how ‘out of the box’ innovation can transform the press room.
For over a century, Antonio Sada & Figli Spa has been a benchmark for packaging production in Southern Italy. Recognised in 2020 as an ‘Historic Enterprise of Italy’, the company is the heart of the Sada Group, an industrial powerhouse divided into corrugated and folding carton divisions.
Partnering with them is BFT Group, who specialises in automatic inking systems and carbon fibre doctor blade chambers.
Beyond the limits of original equipment
Like many high-level converters, Sada was initially skeptical about installing non-OEM components on their primary production lines. Modifying international caliber machines such as the BOBST Masterflex and the EMBA 245 is not a decision taken lightly.
However, Sada’s technical team faced a double obstacle: neither original manufacturer offered proprietary carbon fibre solutions for print unit upgrades. Furthermore, staying tied to original spare parts made it technically impossible to standardise components across different machine brands.
By choosing BFT Carbon solutions, Sada gained access to aerospace grade material technology and finally achieved component standardisation across different presses, simplifying spare parts inventory and operator training.
A step by step approach
The transition to carbon fibre was measured and data driven. The project began with a single doctor blade chamber installed on the EMBA 245. This trial allowed BFT to demonstrate the real world value of its engineering.
Based on feedback from this initial test, BFT technicians developed a tailor made additional washing solution integrated directly into the system. Following excellent results, Sada completed the upgrade for the entire line. This success led to a cascade effect: a few months later, Sada moved forward with upgrading the BOBST Masterflex in one go.
Feedback from the Technical Management
“We chose BFT Carbon to merge their innovative technology with our historic printing lines. This combined our plants’ speed with the qualitative precision of carbon fibre chambers. Given our large formats, the lightness and maneuverability of these chambers make a substantial difference for our operators.”
“On the quality front, BFT Carbon eliminated mechanical vibrations typical of old aluminium alloy chambers. The rigidity of carbon fibre ensures constant doctor blade pressure on the anilox roller, allowing for finer screens and ‘fade to zero’ gradients with unthinkable precision.”
“The material’s nature results in less ink buildup on internal surfaces, making wash cycles much faster and more effective. We have seen a massive reduction in waste, saving over 23.8% in water consumption. Furthermore, we’ve achieved a 34.2% annual saving in washing hours, allowing us to increase the number of processed jobs without increasing operating costs.”
Looking Beyond
Engaging with specialised partners like BFT Group opens the door to next generation materials, true standardisation across different brands, and custom engineering. As Sada’s numbers show, higher productivity, superior quality, and a reduction in downtime – bold innovation is the key to remaining a leader in an evolving market.
