Case Study: Packaging Solutions for the Coffee Industry

In a market where coffee is not just a beverage but an experience, a ritual, and a symbol of cultural identity, packaging plays a key role. From preserving aroma to enhancing shelf appeal, every detail is strategic. In this context, Zambelli Packaging positions itself as a technological partner for coffee producers seeking to combine efficiency, flexibility, and sustainability in their production process.

In this case study, we explore how the Bologna-based company Caffè Carracci, with the adoption of the Zambelli AP200W Wraparound machine, optimized its secondary packaging operations to meet highly specific production needs.

The global coffee market is continuously evolving:

• World production for 2023/24 is estimated at 178 million bags, up 5.8% from the previous year.
  Source: International Coffee Organization (ICO), 2023/24 Forecast
• Global consumption is around 175 million bags, showing recovery after the post-pandemic slowdown.
  Source: ICO – Coffee Market Report 2023
• Key drivers of growth include single-serve capsules, premium products, and rising environmental awareness, which is steering the industry toward more sustainable packaging solutions.

In this landscape, packaging is no longer just about protection—it becomes a strategic asset for logistics, branding, and environmental performance.

For a company like Caffè Carracci, secondary packaging must address several critical requirements:

• Flexibility to accommodate different formats: single-serve capsules, stick packs, and rigid bags
• Compact design to fit within limited production space
• Quick format changeovers to support a varied product range
• Sustainability, using recyclable materials and energy-efficient technologies
• Operational efficiency and consistent product quality across all batches
  
  

To meet these challenges, Caffè Carracci selected the Zambelli AP200W wraparound machine — a compact, versatile, and highly efficient solution for secondary packaging.

This machine packs products into wraparound cartons, providing the ideal balance of product protection, shelf appeal, and logistical optimization.
 

As part of the complete system, a Pick and Place robot—also supplied by Zambelli—was integrated for palletizing purposes only. It is important to note that the robot is not part of the wraparound machine itself but functions downstream in the line.

The AP200W is an intermittent-motion wraparound machine, engineered for maximum control and precision throughout the packaging cycle. Unlike continuous-motion systems, it performs:

• Product separation
• A temporary stop for accurate positioning
• A controlled push into the carton

The system includes:

🔄 Compartment-style bag feeder: maintains product orientation and order during transfer
📦 Carton forming and positioning unit: picks and assembles flat cartons into the desired wraparound shape
➡️ Bag insertion system: pushes the bags into the pre-formed cartons with precision and stability

Supported formats:
📏 1 kg bags – 3x2 wraparound carton configuration
📏 500 g bags – 6x2 wraparound carton configuration

Caffè Carracci has reported concrete, measurable improvements since adopting the AP200W Wraparound solution:

✅ Quick and intuitive format changeovers via touchscreen interface
✅ High accuracy in product alignment and insertion
✅ Compact footprint, suitable for space-constrained production areas
✅ Adaptability to eco-friendly Wraparound cartons
✅ Outstanding energy efficiency: Zambelli’s heat tunnels, equipped with advanced insulation and power management, consume up to 97% less energy than industry-standard systems

Zambelli Packaging delivers innovative, reliable, and sustainable solutions for the coffee industry:

• Modular and scalable technologies to grow with your business
• Custom-designed lines tailored to your specific packaging needs
• Energy savings and waste reduction, improving sustainability and lowering operating costs
• End-to-end support, including training and ongoing technical assistance

🎯 Ready to optimize your packaging process and turn your line into a competitive advantage?