Interview with Aurélie Gasiglia, Product Marketing Manager, at FEFCO 2025.
What are you presenting today at FEFCO?
Today, I’m introducing the next evolution of our rotary die cutters — the DRO with UPack. This solution is designed for converters who need to produce complex die-cut boxes. It takes our existing DRO platform to the next level, and I’ll explain why.
What inspired the development of the UPack system?
The main driver was the rising expectations of brand owners. They no longer want simple boxes with minimal printing and basic die cuts. They’re asking for added-value packaging — boxes with complex die cuts, precise scoring, and vibrant multi-color printing. The Upac was developed to meet these demands and deliver top-tier quality not only in printing, but also in scoring and die cutting.
BOBST is a global leader in packaging equipment, offering advanced solutions for corrugated converters — including rotary die cutters, flexo folder gluers, and robotic automation. Their technologies help boost print quality, scoring precision, and production flexibility.
Can you walk us through how the system works?
Sure. Let me show you a box produced on a standard DRO — the kind we’ve offered for years. Traditionally, these machines print from the bottom, allowing for multiple colors. Since 2022, we’ve also added top printing capabilities — typically one color — to enhance flexibility.
BOBST has offered top rotary die cutting for over 30 years, which includes top creasing. When you crease from the top, the box is erected with color on the outside and clean folds. That’s what you see in this sample — vibrant bottom printing, one top color, and top-side creasing.
Now, with the UPack, we’ve added a bottom scorer. This allows us to crease from the bottom, which means the box can be erected with color on the inside — a feature increasingly important for e-commerce and premium branding.
What’s the impact of bottom scoring on box performance?
It’s a game-changer. By creasing from the bottom, we control how the box folds and where the printed surfaces appear. For example, in this sample, we printed multiple colors from the bottom, one color from the top, and creased from the bottom — resulting in a box with full-color interior graphics.
Can the system handle both top and bottom scoring?
Yes — and that’s the real breakthrough. With the DRO + UPack, we can now score from both sides of the sheet. This double creasing enables complex structural designs and superior fold quality. Even with lightweight or recycled papers, the crease lines remain clean and intact — no cracking, no fiber damage.
What does this mean for converters?
It means more flexibility and higher performance. You can still produce traditional boxes with vibrant exterior printing, but now you also have the option to create interior-printed boxes, double-scored structures, and premium designs — all on the same machine.
How did you achieve this level of innovation?
Innovation, smart people, and a lot of hours of work — that’s the honest answer.
Final thoughts?
With the DRO + UPack, we’re unlocking new converting potential. It’s not just an upgrade — it’s a new standard for what rotary die cutting can achieve.
Thank you for your time. Thank you for the interview!
Thanks very much!
Reporting by Igor Tkalenko – corruga.expert
