Box Marche Case Study: A People-Centered Approach to Automation

From Agricultural Roots to a Modern Manufacturing Leader 

Box Marche’s story began in 1969, a farmer’s family whose entrepreneurial vision transformed agricultural roots into a thriving packaging company in Corinaldo, Italy. The company’s symbolic sculpture, Flusso Vitale (“Vital Flow”), captures this journey from land to enterprise, representing the evolution from farming to innovation. As CEO Tonino Dominici explains, the sculpture tells the story of a business that “is born from the earth and then becomes a company.” They never forget where they come from. 

Despite its growth, Box Marche has remained deeply connected to its values. Through initiatives such as the Bosco di Fonte Mora employee forest and its Radici Comuni (“Common Roots”) program, the company emphasizes shared values of “love of beauty, love of nature, love of work, and love of respect” as the foundation of its culture. 

Central to this philosophy is a belief that people are the company’s greatest asset. 

“The technology we are most proud of is the one that goes home at night.” 

By “technology,” the company means its employees. 

“People are the only resource that increases in value over time.” 

As Box Marche expanded, leadership faced a critical challenge: how to make the work safer, healthier, and more attractive for employees, while increasing productivity. 

Challenge 1: Physically Demanding Manual Packing Work 

Before the introduction of IMPACK’s VIRTUO and ERGOSA systems, end-of-line packing was entirely manual. 

Workers spent entire shifts lifting cartons, loading boxes, and handling products repeatedly. The work was exhausting and physically taxing. 

One operator described the reality of the job: 

“You spent your days picking cartons up and putting them into boxes.” 

Employees often finished their shifts completely exhausted. The repetitive process also constrained production speeds because workers could only sustain a limited pace. 

How IMPACK Solved the Problem 

The IMPACK VIRTUO Automatic Packer was integrated on a line dedicated to heavy folding-carton and corrugated straight-line boxes. The ERGOSA Semi-Automatic Packer was integrated on a finishing line dedicated to very complex auto-bottom boxes. 

Box Marche selected VIRTUO and ERGOSA with a clear objective: 

“The most important challenge for us was increasing productivity while maintaining and reducing people’s manual work.” 

By automating carton collection and packing operations, VIRTUO dramatically reduced repetitive handling. Operators no longer spent entire shifts lifting and loading cartons. 

As one employee explained: 

“While the operator at the end of the line could place cases onto VIRTUO with very little effort, we could keep increasing the speed of the folder-gluer.” 

The result was a significant reduction in manual labor while simultaneously improving throughput. 

Challenge 2: Reducing Ergonomic Risks and Improving Employee Well-Being 

Manual packing created serious ergonomic concerns. Employees experienced repetitive strain, posture-related discomfort, cuts from carton board handling, and long-term musculoskeletal risks. 

Management recognized that worker health had to become a strategic priority. 

“The purpose was to facilitate people’s work.” – Tonino Dominici, CEO and owner 

The company wanted technology to improve quality of life, not simply increase production. 

How IMPACK’s VIRTUO and ERGOSA Packers Improved Health and Morale 

“These technologies brought the smiles back to our workers’ faces.” says Mr. Dominici. 

The CEO estimates: 

“We reduced by perhaps more than 50% all the illnesses and problems associated with manual handling—carpal tunnel syndrome, joint pain, posture-related pain.” 

Beyond physical improvements, automation transformed employee morale. 

“The main objective was to help people’s health—to make them work less. Maybe produce more, but work much better.” 

With less physical strain, employees gained more time to focus on quality, problem-solving, and continuous improvement. 

“We gave people more time to think and therefore they can find solutions more easily.” 

Challenge 3: Recruiting Talent in an Industry Burdened by Misconceptions 

Today, one of Box Marche’s biggest challenges is attracting new talent. 

The company struggles against outdated perceptions of manufacturing work. Many potential candidates still associate factory work with physically demanding, low-skill labor. 

“The common perception is that the factory is a place where people suffer and toil.” - Mr. Dominici 

This misconception extends to educated candidates. 

“If you ask a high-school graduate to become an operator, they’ll say no.” - Mr. Dominici 

In reality, modern manufacturing at Box Marche requires technical knowledge, process control, teamwork, and digital competencies. 

As Mr. Dominici explains: 

“The operator is increasingly a process controller.”  

The challenge is helping prospective employees understand that manufacturing careers today are technology-enabled, intellectually engaging, and team-oriented. 

How VIRTUO and ERGOSA Support Recruitment and Employer Branding 

The introduction of the IMPACK solutions has become a powerful demonstration of Box Marche’s people-first philosophy. 

Rather than replacing employees, automation has elevated their roles. 

Employees now spend less time performing repetitive physical tasks and more time monitoring processes, solving problems, and contributing ideas. 

The systems are also easy to learn and highly accessible. 

“The IMPACK machines are very friendly and very intuitive.” - Mr. Dominici 

Operators report that training took only a few days and that virtually anyone in the department can operate the equipment confidently. 

By showcasing modern technology, safer working conditions, and a strong employee-centered culture, Box Marche is actively challenging outdated stereotypes and positioning itself as an employer of choice. 

Tangible Results 

The implementation of the VIRTUO and ERGOSA packers delivered measurable improvements across productivity, health, and employee engagement. 

Key Outcomes 

Productivity 

•  67% speed increase on the VIRTUO equipped folder-gluer line.  

Health & Ergonomics 

• More than 50% reduction in manual-handling-related health issues. 

• Fewer cases of carpal tunnel syndrome, joint pain, and posture-related discomfort. 

• Reduced sickness-related absences. 

Employee Experience 

• Significant reduction in physical fatigue. 

• Greater focus on quality and problem-solving.

• Improved morale and engagement.

• Easy adoption through intuitive operation and minimal training. 

IMPACK Solutions - A Natural Extension of People-First Values 

For Box Marche, automation was never simply about producing more. It was about creating a workplace where people could thrive. 

Through the implementation of the ERGOSA and VIRTUO Packers from IMPACK, the company successfully reduced physically demanding work, improved employee health, enhanced productivity, and strengthened its ability to attract future talent. Most importantly, the project aligned with Box Marche’s core belief that technology should serve people. 

As Mr. Dominici summarized: 

“The introduction of technology should create well-being for people.” 

And in Box Marche’s view, the ultimate measure of success is not only increased output, but a workplace where employees leave healthier, happier, and ready to return the next day.