Optimisation of the corrugator production process

Sada Packaging is the paper converting company of the Sada Group. Founded in 2006, it produces flat and microwave cardboard boxes with offset technology. It is a young company able to offer, using the most advanced technologies, high quality products to Italian and multinational customers with very demanding requirements. In particular, it serves the food and consumer sector.



The department dedicated to the production of microwave board had high processing and set-up waste:

  • 10% of waste per year;
  • 114 hours per year spent on waste production.


Reduction of process and set-up waste through implementation of 5S and DOE projects.



Cost reduction
Reducing waste
Programme duration
Programme amortisation period

In addition to the benefits listed above, in general, significant improvements have occurred in the affected production areas as a result of project implementation, evidenced by:

  • A tidier, cleaner and safer working environment;
  • A reduction in process variability with increased efficiency and productivity;
  • A positive impact on staff skills, motivation and culture, which has contributed to a more effective and continuous improvement-oriented working environment.

To bring continuous efficiency to our company, we identified Redlab as the right partner to achieve our goals of reducing process waste and optimising corrugation process set-up times.

During the implementation phase of the integrated 5S&DOE project conducted by Redlab, our organisation experienced significant benefits that exceeded our initial expectations. These benefits have been observable since the implementation phase and have been consolidated over time.

We chose Redlab because of their practical approach. The Redlab team has, in fact, worked alongside our employees, indicating the strategy to be followed and actively supporting the implementation of the interventions until the result is achieved.

In summary, Redlab identified the strategy to be pursued to achieve our objectives by working closely with our teams and making the most of the resources in the company.
in the company, implemented the identified solution and transmitted a working method that empowered our teams with a view to continuous improvement.

Mirko Aliperta

General Manager

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