Cama has successfully taken on one of its most demanding assignments yet: designing innovative coffee capsule packaging that can bring high‑quality Italian coffee to the world. After a meticulous briefing and months of research and technical consultancy, the machines are being installed and the new aluminium capsules are ready for take‑off.
A demanding briefing and a high‑tech challenge
In the business‑to‑business world, long‑term relationships grow out of listening to customers and supporting their needs. While some projects are straightforward, others require in‑depth studies, tests and creative problem solving. This was one of those challenges. A leading coffee company asked Cama to replace its polypropylene capsules with 100 % recycled aluminium coffee capsules and to package them in a way that protects quality over long journeys from northern Italy to every continent.Replacing plastic with recycled aluminium
The goal was clear: maintain premium coffee quality while moving to sustainable capsules and eye‑catching secondary packaging. Aluminium capsules offer recyclability but need extra protection because they scratch more easily than plastic. Cama’s Packaging Department worked closely with the customer, acting as a true partner throughout the process. According to Area Manager Sergio Cornago, the brief demanded capsules that were compatible with all existing coffee machines, adapters where necessary, and secondary packaging capable of passing strict transport tests. The team rose to the challenge, delivering a functional, high‑aesthetic solution that also gives the end consumer a memorable unboxing experience.Co‑creating a premium packaging experience
To protect the aluminium coffee capsules in transit, Cama designed a honeycomb‑style box formed from flat die‑cut sheets. Inside, alveolar dividers keep each capsule separate, preventing dents and scratches while showcasing the product on the shelf. Everything is produced on a single monoblock line, and Cama’s System Engineering Division automated the entire process. The result is a seamless blend of innovative coffee capsule packaging and state‑of‑the‑art manufacturing.Boosting productivity and sustainability
This project also required re‑engineering the customer’s existing machines so they could handle the new packaging. Cama developed a pre‑opening system for the interleaf that separates capsules in the box and integrated ten fast, intelligent robots. Each module consists of two independent units working in sync to fill boxes from four lanes. Productivity can be adjusted from four to two lanes, reducing energy consumption and providing a built‑in backup during maintenance. Overall, the line is designed to produce 850–900 capsules per minute, highlighting how sustainability and performance can go hand in hand.Delivering sustainable innovation worldwide
As the system is installed at the customer’s facility, this complex challenge is reaching a successful conclusion. Cama’s solution proves that innovative coffee capsule packaging can combine technology, sustainability and design, using 100 % recycled aluminium without compromising the taste or presentation of the coffee. The project reinforces Cama’s role as an ideal partner for brands seeking to innovate responsibly and deliver premium coffee experiences across the globe.
