A record-breaking installation (the 5,555th cutter) recently took place at Grafiche Lama, celebrated with a commemorative plaque awarded by Polar to the Piacenza-based company. Grafiche Lama has also recently joined the La Prensa group, enabling further growth and development within a broader context, with a focus on the in-mould label market
The end of 2024 will undoubtedly be a milestone in the over fifty-year history of Grafiche Lama and its CEO Dario Fulgoni, who has led the company since 2013. When he decided to renew the cutting department, he certainly did not imagine that the purchase of the Polar cutter, the 5,555th installed in Italy, would be celebrated. Polar, represented in Italy by Heidelberg, has been operating in the market for many years. Given the longevity of these systems, these are significant numbers that highlight the widespread adoption of a technology often underestimated or taken for granted. However, these systems make a substantial difference in printing and converting companies, where Polar cutters are highly appreciated for their cutting quality and remarkable mechanical reliability, enabling decades of trouble-free operation.
Experts in in-mould labels
Grafiche Lama, based in Piacenza with approximately 30 employees, uses the Polar cutter in conjunction with three Heidelberg offset printing machines and the binding department. Here, they produce In-Mould Labels (IML) printed on different plastic materials, with light grammage, for permanent decoration of plastic containers, as well as paper labels for the canning industry. “In 2013, when my family and a partner acquired the company, we decided to focus on the IML market. This decision was reinforced by a previous acquisition of a company specializing in this field and our ambition to grow in a niche sector with enormous potential. Any plastic object that can be decorated finds a valuable ally in in-mould technology. We maintain close collaboration with our clients: in-mould labels are highly specialized products requiring deep knowledge of the production process, materials, inks, and handling of semi-finished products that are challenging to manage. As a result, we are often considered an external department of our clients’ companies”, says Dario Fulgoni, CEO of the company. Their work also extends to commercial printing and cardboard converting, accounting for about 35% of production, as part of a diversification strategy, but at the center there are in-mould labels. The company’s global revenue slightly exceeds €5 million, with an export rate of 35%.
From printing machines to cutting and binding: partnership with Heidelberg
This growth has been supported by a robust investment strategy in technology, evidenced by the two new Heidelberg Speedmaster 70×100 machines: a five-color model introduced in 2021 and a six-color model at the end of 2023, both dedicated to in-mould label printing. “In my experience in-mould sector, I believe Heidelberg printing machines are the best available. They are ideal for printing on very thin materials that must not retain any static electricity when finished, otherwise subsequent handling would be impossible. It’s one thing to state this on paper, but another to achieve really this result, and with Heidelberg, we know from experience that it’s achievable”, says Fulgoni.
The printing department also includes a two-color Heidelberg machine for pharmaceutical work and a couple of digital printing machines. The production cycle is completed with special rotary die-cutters designed and built to meet the specific needs of IML market. These machines are key to Grafiche Lama’s success, offering extremely short setup times and exceptional productivity. In line with the goal of equipping each department with the best available technologies and considering investments in software, prepress, printing, and converting, the cutting department has recently undergone a significant upgrade. “Our old Polar cutter from 1998 worked perfectly, but we seized the opportunity offered by Industry 5.0 to modernize this step in our production chain, improving efficiency and energy consumption. The new cutter features component upgrades that reduce energy consumption by 2 amps compared to the previous model. More importantly, it has an automatic standby system that activates after 5 minutes of inactivity, significantly reducing the cutter’s overall energy usage”, adds Fulgoni.
Over the past two years, the company has increased its business volume and production by about 50%, with delivery times ranging from 15 to 20 days. This production primarily consists of small batches, making stockpiling impossible and so we need an efficient organization and high-performance technologies.
“Our long-standing relationship with Heidelberg Italia has led to several installations over the years, including a folder in 2020. This partnership, especially with CEO Dario Fulgoni, has enabled the company to gradually renew its entire production technology, always with Heidelberg as the reference point. This makes us particularly proud to contribute to the success of these companies. The 5,555th installation in the Italian market underscores the leadership of these systems in the graphic industry and highlights their flexibility and versatility, accommodating applications beyond paper, such as plastic materials in this case”, concludes Lorenzo Ariberti, postpress manager at Heidelberg Italia.
Joining La Prensa Group
Officially completed last December after months of discussions to plan the integration properly, Grafiche Lama has joined La Prensa group. This Milan-based company is rapidly expanding, specializing in the production of paper and glue labels for the food and beverage sector. La Prensa is extending its market reach through strategic acquisitions in related fields, such as self-adhesive labels, in-mould labels with Grafiche Lama, and flexible packaging. What sets La Prensa’s acquisitions apart is that the original owners remain in charge of the acquired companies, ensuring continuity and preserving their heritage. This approach offers excellent prospects for future growth and development within a solid and rapidly expanding organization.
