CAMA IS REINVENTING COFFEE CAPSULE PACKAGING WITH 100% RECYCLED ALUMINIUM
For over forty years, Cama Group has been a global leader in automated packaging machinery. The Italian company combines technological innovation, energy efficiency and expertise in packaging design. Its latest project, a line dedicated to 100% recycled aluminium coffee capsules, perfectly illustrates this approach: designing more sustainable packaging without sacrificing quality or industrial efficiency.
This line was developed to replace plastic capsules with a recyclable material, while ensuring that aromas are preserved over long distances. A technical challenge with high added value.
Working with 100% recycled aluminium is a challenge for any packaging manufacturer. Lighter and more fragile than polypropylene, it requires extremely precise handling. Cama therefore implemented a development strategy based on co-creation and real-world testing in order to design a tailor-made industrial packaging solution. The project had to meet several requirements: full compatibility with existing coffee machines, resistance to logistical constraints and an enjoyable unpacking experience. It is this ability to link market expectations to advanced technical design that is Cama's strength. By integrating aesthetic, ergonomic and environmental criteria from the design stage onwards, the company has established itself as one of key players in sustainable professional packaging.
Protective and attractive packaging design
To ensure the capsules are protected, Cama has developed an innovative honeycomb box made from flat-cut cardboard sheets. Inside, each capsule is isolated in an individual cell forming a honeycomb structure. This system protects the product while providing an attractive presentation.
The entire process is managed by a fully automated monobloc machine, combining mechanical precision with intelligent software. Robotic arms ensure millimetre-precise positioning, guaranteeing speed, reliability and energy efficiency. This design illustrates Cama's expertise in the world of packaging, where every innovation is based on a global vision of production.
Energy performance and intelligent automation
One of the strengths of the project lies in the complete reconfiguration of existing lines to accommodate the new packaging. Cama has designed a system for automatic pre-opening of the dividers, coupled with ten intelligent robots working in synchronised modules. Each unit can operate in two or four-line mode, depending on the desired speed, which optimises energy consumption and ensures redundancy in case of maintenance.
With a capacity of 850 to 900 capsules per minute, the line offers a rare balance between speed, reliability and sustainability. It demonstrates how a modern packaging machine can reconcile industrial performance and environmental responsibility, meeting the demands of the global coffee market.
Packaging as a vehicle for sustainability
Beyond its technical prowess, this project illustrates a vision: that of packaging that conveys meaning and commitment. By adopting 100% recycled aluminium, Cama Group and its client are fully embracing the circular economy. The line not only reduces environmental impact, but also enhances the premium perception of the product thanks to its sophisticated packaging design.
For Sergio Cornago, Regional Manager at Cama, ‘This project demonstrates that it is possible to combine technology, sustainability and design.’ By combining mechanical innovation, intelligent automation and eco-design, Cama is asserting its role as a key partner for brands wishing to innovate in line with ecological standards.
Cama will be exhibiting at ALLFORPACK EMBALLAGE PARIS 2026, showcasing some of the major innovations at the show. The event will bring together leaders in industrial packaging and packaging design, offering a comprehensive overview of the technologies shaping the future of the sector. In a context where sustainability and performance are no longer mutually exclusive, the show has established itself as the global hub for responsible solutions. Cama's presence at the show perfectly illustrates this new generation of companies that are making professional packaging a lever for innovation, competitiveness and sustainable transformation.