Thinking Outside the Flat-Pack Box

Sitma has introduced FlatPack, an automated paper-based wrapping solution for furniture panels, designed as a primary packaging system to replace plastic packaging in industrial
production environments.

Developed in collaboration with a leading global furniture manufacturer, FlatPack combines sustainability with industrial performance, enabling furniture manufacturers to reduce plastic use without compromising packaging protection, operational continuity, or logistics efficiency. Built on Sitma’s established expertise in paper-based packaging, the system has been engineered to meet the specific requirements of furniture manufacturing and distribution.

FlatPack enables manufacturers to move beyond plastic while maintaining productivity. Through fit-to-size continuous motion primary packaging, it delivers compact and secure packs that reduce material usage and support efficient logistics. At the same time, the inward-folded wrapping geometry allows for optimized palletization, improving space utilization and handling stability across the supply chain.

In addition to wrapping, FlatPack integrates complementary packaging operations within the same workflow. The system manages the insertion of instruction manuals and leaflets, as well as the integration of hardware toolboxes or assembly kits, ensuring all product components are securely contained within the final package.

Unlike many paper-based alternatives, FlatPack is designed to perform consistently across real production and logistics environments. It ensures reliable product protection during storage, transport, and in-store handling, while maintaining a clean and uniform retail appearance. This makes it not only a sustainable solution, but also a practical and scalable approach for large-scale furniture manufacturing operations.

With the shift from plastic film to printable paper, FlatPack also transforms packaging into a functional communication surface. Manufacturers can integrate information, instructions, branding, and sustainability messaging directly onto the pack, reducing additional materials while enhancing customer interaction at the point of sale.

“FlatPack represents a major step forward in combining sustainability with industrial performance,” says Stefano De Marco, CEO of Tecnau and Sitma. “With this solution, we enable manufacturers to eliminate plastic from primary packaging while maintaining the efficiency, protection, and scalability required in modern production and logistics environments. It reflects our commitment to delivering tangible, production-ready innovations that support our customers’ transition towards more sustainable operations.”

Built for modern production environments, FlatPack supports automated workflows and integration with existing packaging lines. Its flexibility allows manufacturers to adapt to different panel sizes and production requirements while maintaining consistent performance.

FlatPack represents a new standard in furniture packaging, where sustainability and industrial performance are no longer in conflict. It combines paper-based packaging, automation, and logistics optimization within a single solution.

It’s in the Bag

Sitma also recently introduced PackHub, a compact automated bagging system designed to simplify and accelerate order fulfillment operations while easily integrating into existing packing workflows.

Developed to support growing e-commerce and fulfillment environments, PackHub automates key steps of the bagging process, including bag feeding, orientation, and labeling, helping operators work more efficiently while maintaining a simple and intuitive workflow. By streamlining repetitive tasks, the system can reduce packaging time by up to 50% per order, increasing productivity without requiring a complete process overhaul.

At the core of the system is a high-capacity hopper holding up to 500 bags, enabling continuous production with a large buffer capacity and minimizing operator intervention. Bags are singulated through a precision friction feeder and automatically rotated into the optimal position for ergonomic product insertion. A vacuum cup holding station stabilizes the bag during packing, while an integrated labeling unit prints and applies labels directly to the envelope.

PackHub is designed for flexibility and easy integration. Its compact footprint makes it ideal for facilities with limited floor space, while the wheeled frame allows the unit to be easily repositioned.

“PackHub was developed to offer a practical automation step for operations looking to increase packaging productivity without completely redesigning their workflow,” says De Marco.  “By automating the most repetitive tasks while keeping operator interaction simple and intuitive, PackHub helps companies scale their fulfillment operations efficiently.”