meridionalplast, based in andria, was founded in 1977 by Salerno pasquale and has specialized in the production of flexible packaging for nearly fifty years. Customer satisfaction is a fundamental priority for the company: the careful selection of raw materials, the production of film with corresponding graphic design, and the customization of packaging always ensure an optimal result. With this machine, which sets new standards through the combination of quality factors such as performance reliability, process consistency, efficiency, cutting-edge technology, and extreme versatility, meridionalplast continues its growth
Passion, professionalism, and teamwork have enabled the company to develop and gain a prominent position not only in the Apulian market but also throughout Italy. Today, the company employs over 50 people and is part of the larger “Gruppo Salerno”.
It spans an area of over 20,000 sm and has a continuously expanding production department, allowing it to create high-quality products with excellent performance in terms of strength, barrier properties, and shelf life.
Technological evolution has been constant over time, and especially in recent years, meridionalplast has invested in acquiring Industry 4.0 machinery that combines well-established and functional mechanics with new-generation electronics and software. This aims to start a digital transformation process, offering increasingly higher quality products while also reducing raw material and energy consumption, with beneficial effects on the environment.
Respect for the environment
meridionalplast has always been highly sensitive to recycling, environmental protection, and the use of compostable and biodegradable materials. The company can produce a wide range of eco-sustainable packaging options, using entirely natural raw materials. “Respect for the environment and a constant focus on recycling and the circular economy have long been our core values. We have developed several green solutions that reconcile quality and sustainability; recycling and the circular economy principles apply to all stages of our production process, from raw material selection to reusing production scraps”. says Pasquale Salerno, the company’s sole administrator.
To increase the sustainability of its production process, the company has been experimenting with alternatives to fossil-based raw materials, known as bio-based polymers. For years, it has incorporated natural-origin granules into its production cycle, such as those derived from the transformation of sugars found in corn, beet, and sugarcane, enabling the production of biodegradable and compostable plastic films that can be entirely disposed of in organic waste (rather than plastic, as is the case for conventional biodegradable packaging).
In addition to natural-origin polymers, meridionalplast also uses resins made entirely from post-consumer recycled plastics, certified as “Plastica Seconda Vita”. This recycled raw material produces a fully recyclable product. Furthermore, meridionalplast has implemented an internal regeneration plant that allows it to recycle and reuse all production waste, creating compostable granules. These waste materials are reused to produce new flexible packaging (such as bags or films) or supplied to other companies for recycling into various products (e.g., funnels, ice molds, bread baskets, etc.). “Thanks to this virtuous cycle and collaboration with other local businesses, we significantly reduce waste and environmental impact”, says Pasquale.
Pallet reuse
meridionalplast’s commitment to sustainability extends to the final stages of its production cycle, including transportation. The company has been awarded the PRS Green Label for actively participating in a sustainable network of producers, processors, transporters, and environmentally responsible traders aiming to establish an efficient pallet reuse system. Alongside other PRS partners, it collaborates towards a circular economy: as a plastics producer, it provides shipping information for pallets; polymer converters then separate and return pallets after use: then PRS collects, repairs (if necessary), and redistributes pallets to the next customer.
Products and target markets
meridionalplast’s target market is divided into two main segments: food and non-food. The food sector accounts for about 80% of its revenue, with major clients including dairies, bakeries, pasta manufacturers, and fruit and vegetable producers. Key products in this segment include bags and reels for packaging of baked goods, fruits, vegetables, and dairy products; greaseproof paper and bags; freezer bags; vacuum rolls and bags; freshness-preserving pouches; hamburger discs; and macro- and micro-perforated films.
In 2018, the company patented a new decorative packaging model, “Quadrifoglia”, designed for dairy products such as burrata (which originated in Andria). This packaging has been highly successful not only in Puglia but also across Central and Northern Italy.
For the non-food sector, meridionalplast produces items for pharmacies, medical stores, and retail boutiques, including waste separation bags, biodegradable and compostable shoppers, soft-handle bags, pharmacy bags, garment covers, and mailing pouches.
A new flexo machine: XD Pro by Koenig & Bauer
“The need for a new flexo printing machine stems from the necessity to improve our productivity and offer increasingly high-quality products to enhance our competitiveness. The flexible packaging sector is constantly growing, but this growth must align with international Green Economy guidelines. Additionally, the food sector is characterized by many similar products, where the only distinguishing factor is packaging, designed to evoke emotions”, says Pasquale.
The company’s goal is to specialize in flexo printing, meeting the increasing and specific demand for food packaging while fostering continuous growth and innovation.
After thorough research, meridionalplast selected the XD Pro by Koenig & Bauer.
“The decisive factor in our choice was an insightful meeting with ing. Andrea Dallavalle, Sales Director of Flexo at Koenig & Bauer Italia. His expertise and availability helped guide us toward the technical option best suited to our production and organizational needs. The XD Pro, combining nearly 50 years of Italian experience in the flexo printing market with German engineering, is the industry leader, offering exceptional reliability, process consistency, and versatility with cutting-edge technology”, explains Pasquale.
This printing machine is ideal for meeting just-in-time market needs, allowing greater agility in short-run production with an unrivaled ergonomic design, easy access to printing units, and advanced automation for quick changeovers with minimal waste. The modular design of this fully automated CI flexo printing machine allows for inline integration of various printing, finishing, and converting modules, including specialized applications and complementary printing techniques such as gravure, offset, or digital printing.
The XD Pro achieves excellent operating results in terms of technical performance for both long and short runs, thanks to a rigid mechanical structure and superior printing unit technology, with maximum efficiency and minimized energy consumption, thanks to a straightforward mechanical design and more rational industrial integration of all machine components and accessories. Stable construction, central drum and convenient automated processes form the basis for high productivity.
The XD Pro that entered the company in October 2024 has 8 printing units. It is very versatile because it allows customized configurations according to the needs and type of printed products, which can be plastic, paper, and cardboard.
The features of the XD Pro are in line with the goals of environmental sustainability and energy efficiency that meridionalplast has been pursuing for some time, in compliance with international guidelines related to the Green Economy, here are some of them: DriveTronic®, machine control system of highest precision, long-lasting reliability for high productivity and energy efficiency; DryTronic®, high-efficiency drying system with lower energy consumption; PrintTronic®, automatic print pressure setting system with minimized material waste; WashTronic®, automatic inking and washing system with optimization of ink and detergent use and thus lower environmental impact; GAMA VIS-G29, automatic ink viscosity control system with reduced consumption of dilution solvents with drastic reduction of consumption and waste.
The advantages guaranteed by the investment
XD Pro will allow meridionalplast to produce very high quality prints in up to 8 colors, with colors very faithful to the real ones and, therefore, with a high quality result, being able to meet the ever-increasing demand for personalized packaging, with consequent acquisition of new customers (especially in the food and GdO sector), until now impossible to satisfy with the technologies present in the company.
Moreover, this installation marks another step in the company’s digital transformation journey, enhancing operational efficiency and environmental sustainability. Equipped with Industry 4.0 technology, the XD Pro allows real-time monitoring of the production cycle and resource performance, minimizing errors and production waste, reducing costs, and boosting production efficiency.
“Faster processes and fewer errors will not only improve existing products but also allow us to experiment with new items and expand our market share.
The investment will also benefit our workforce, as new technologies provide real-time, precise work instructions for assembly, maintenance, and quality control: evolution and productive growth that go hand in hand with social and personal development”, concludes Pasquale with satisfaction.
