From challenge to change: how Cartonstrap supports a more efficient and responsible ceramic production

Packaging is a critical part of ceramic production. It influences how tiles are moved and how they’re handled during installation. It also affects sustainability targets and compliance with increasingly detailed regulations. For manufacturers, these are not marginal issues, they are part of how the entire process performs.

Cartonstrap was developed by System Ceramics to address these aspects with a precise solution: a plastic-free machine that couples and protects tile stacks using only cardboard and hot melt glue. It integrates with existing packaging lines, improves handling on site, and helps reduce material waste without adding complexity to the workflow.

Italgraniti, an Italian reference in the production of porcelain gres, has been among the first manufacturers to install this machine. “In 2024, we made the decision to adopt Cartonstrap because sustainability is central to our process” the company explains. “We’ve focused in particular on reducing plastic in packaging, and this machine allowed us to eliminate the use of strapping”.

A solution that answers real production needs

Cartonstrap works by applying four die-cut cardboard corners to each stack of tile boxes. These corners are pre-cut, creased and glued using hot melt adhesive, a widely used and reliable bonding solution in ceramic lines. The result is a unified, stable stack that is easy to handle, ready to palletize, and protected during transport.

This configuration provides multiple benefits in one step. Each box is physically protected at the corners, reducing the chance of edge damage. At the same time, the entire stack gains structural integrity, even under vertical pressure, without needing plastic straps.  

The format also facilitates handling further down the line: at the construction site, installers can simply cut the cardboard corner and remove one box at a time, instead of dealing with bundles bound by plastic strapping. “That’s a real improvement” Italgraniti confirms. “We avoid the risk of five or six boxes falling together just because one strap was cut”.

Integrated performance, simplified design

Cartonstrap was built with integration in mind. Its compact structure allows it to fit into existing plant layouts, particularly downstream of System Ceramics’ packaging machines, but also as a retrofit solution. It features a single squaring and gluing module, two lateral cardboard feeders, which can be reloaded without halting production, and a throughput capacity of up to five stacks per minute. All functions, including the dimensions of the cardboard corners, are controlled via software, making it easy to adapt to different stack heights or format changes without mechanical intervention.

Compatible with a wide range of cardboard types, including recycled kraft paper, Cartonstrap supports die-cut formats up to 1200 by 200 millimeters and handles stacks between 75 and 200 millimeters in height. These specifications make it suitable for high-volume, variable-format environments, exactly the kind of conditions where packaging performance must be reliable and adaptable at once.

A clear answer to sustainability goals

Replacing plastic strapping is a step toward measurable, structural sustainability. According to internal estimates, each Cartonstrap unit can eliminate up to two million meters of plastic strapping per year. The use of cardboard (especially recycled) drastically reduces packaging waste and simplifies compliance with environmental regulations.

For companies exporting to markets like Germany, Cartonstrap also provides a direct advantage in terms of regulatory alignment. It supports full compliance with VERPAGK, the German regulation that limits the volume and type of packaging for imported goods. In a European context where legal frameworks are evolving fast, having a system that anticipates and responds to these changes is a competitive edge.

Protecting the product and the process

One of the most underrated aspects of Cartonstrap is its contribution to downstream value. By protecting each box individually, it reduces the likelihood of claims linked to chipped corners or collapsed stacks. And by facilitating safe, controlled removal of packages on site, it also reduces the risk of installer injury or product damage.

These are not secondary advantages. They translate directly into fewer losses, better reputation, and a smoother customer experience. They also reflect a shift in how manufacturers are beginning to look at packaging, not just as containment, but as an active part of product integrity.

A technology shaped by vision

Cartonstrap is the product of System Ceramics’ continuous investment in research and development. It reflects a broader strategy: to design machines that serve current needs while anticipating what’s next. In the case of packaging, this means combining automation, environmental awareness, and usability in a single, elegant system.

The decision by companies to adopt Cartonstrap shows the market’s readiness for this change. Producers are no longer looking for incremental tweaks. They are looking for technologies that allow them to align production goals with environmental responsibility, operational flexibility, and regulatory pressure, all at once.

Discover how Cartonstrap by System Ceramics can help redefine your packaging line, improving safety, sustainability and control.