How the installation of BFT doctor blade chambers on BOBST and EMBA lines revolutionized production efficiency, sustainability, and print quality for a historic leader in corrugated cardboard
In the highly competitive world of corrugated packaging, the pursuit of technical perfection is an ongoing journey. On one hand, there is the need to preserve the reliability of established printing lines; on the other, the urgent 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 exemplary case study demonstrates how “out of the box” innovation can radically transform the press room.
For over a century, Antonio Sada & Figli Spa has been a benchmark for packaging production in Southern Italy. Recognized in 2020 as a “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 (BFT Carbon), an emerging Italian center of excellence and a pioneer in advanced flexographic solutions. BFT specializes in automatic inking systems and revolutionary carbon fiber 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 systems. 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 fiber solutions for print unit upgrades. Furthermore, staying tied to original spare parts made it technically impossible to standardize components across different machine brands.
By choosing BFT Carbon solutions, SADA gained access to aerospace grade material technology and finally achieved component standardization across different presses, drastically simplifying spare parts inventory and operator training.
A Step by Step Approach: From Testing to Total Upgrade
The transition to carbon fiber 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 EMBA 245. This success led to a “cascade effect”: a few months later, the client moved forward with upgrading the entire BOBST Masterflex in one go.
Real Results: Feedback from the Technical Management
To understand the impact of this retrofit, SADA’s technical management shared the following insights:
Why choose BFT Carbon?
“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 fiber chambers. Given our large formats, the lightness and maneuverability of these chambers make a substantial difference for our operators.”
Quality of Print:
“On the quality front, BFT Carbon eliminated mechanical vibrations typical of old aluminum alloy chambers. The rigidity of carbon fiber ensures constant doctor blade pressure on the anilox roller, allowing for finer screens and ‘fade to zero’ gradients with unthinkable precision.”
Maintenance and Efficiency:
“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.”
Conclusion: Looking Beyond
The SADA Group experience sends a clear message to the corrugated sector: relying exclusively on OEM manufacturers for technological updates can sometimes limit a line’s potential.
Engaging with specialized partners like BFT Group opens the door to next generation materials, true standardization across different brands, and custom engineering. As SADA’s numbers show higher productivity, superior quality, and a drastic reduction in downtime bold innovation is the key to remaining a leader in an evolving market.
