Production Process

Production Process

Manufacturing Excellence

Manufacturing Excellence

The pillars of our production process

Quick Overview

Innovation and Control

The quality of our products comes from an advanced and integrated production process that combines innovation, precision, and strict quality control.

People and Technology

Every step is carefully managed by a skilled and dedicated team, using cutting-edge technologies to ensure reliability and consistency throughout the process.

Efficiency and Precision

Our three production plants feature state-of-the-art machinery that guarantees maximum efficiency, accuracy, and high performance at every stage.

Plants & Product Capacity

Thanks to continuous investment in cutting-edge technologies,
we ensure high production volumes while maintaining maximum quality and flexibility.

3 facilities

continuous production flow

3 facilities

Alvapack operates three strategically located production facilities, enabling flexibility, fast response times, and continuous production flow.

Production capacity

reliability and delivery continuity

Production capacity

We process between 1,200 and 1,400 tons of raw material per year, maintaining a constant rotating stock of around 400 tons.
This ensures reliable supply, production efficiency, and continuous delivery for all customer orders.

Printing Machines

High-Definition Printing

Printing Machines

  • 6 flexographic printing machines (8-10 colors)
  • 4 lamination lines (solvent and solvent-less)
  • HD printing technology for superior definition

Slitting Machines

Precision and Flexibility

Slitting Machines

  • 15 precision slitters
  • Automated quality control systems
  • Flexible configurations for multiple sizes and formats

Perforating Machines

Custom Perforation

Perforating Machines

  • 2 next-generation laser perforators
  • 2 macro perforators
  • 2 hot-needle perforators
  • Controlled micro-perforation systems
  • Customizable permeability according to product needs
In-House Testing Laboratory

Our Manufacturing Process

Every stage of our production is subject to rigorous quality checks to ensure that every product meets the highest industry standards.

  1. Raw Material Selection
    We carefully select suppliers that guarantee consistent quality, full traceability, and certified compliance with our strict production standards.
  2. Film Extrusion
    The extrusion process is precisely monitored to ensure uniform thickness, optimal transparency, consistent mechanical properties and antifog performances.
  3. Corona Surface Treatment
    Specific surface treatments are applied to enhance anti-fog properties and improve ink adhesion for high-quality printing.
  4. Printing
    Our HD flexographic printing machines reproduce complex graphics with precision, bringing out both brand identity and product appeal.
  5. Cutting and Perforation
    Precision cutting and controlled perforation systems allow full customization to meet packaging and preservation requirements.
  6. Quality Control
    Each production batch undergoes extensive testing to verify thickness, mechanical strength, anti-fog performance, print quality, coefficient of friction (COF), sealability, and hot-tech resistance (heat-seal strength).
  7. Packaging and Logistics
    Finished products are packed with care to preserve integrity during transport and storage, managed through an efficient logistics system ensuring on-time deliveries.
In-House Testing Laboratory

Our Technologies for Printing Plates

We continuously invest in innovative technologies to enhance product quality and production efficiency.

HD Printing Technology

High-definition printing systems ensure sharp detail reproduction, extended color gamut, and superior graphic quality.

CDI QUARTZ Technology

We are implementing CDI QUARTZ, a groundbreaking standard for flexographic printing quality.
Its dual-optic Quartz Optics system merges the advantages of CDI Crystal with the newest Quartz technology, achieving:

  • Imaging resolution up to 4000 ppi (almost double the industry standard)
  • Microcells at 2000 lpi (Q-Cells) for improved ink transfer
  • Print quality equal to or superior to rotogravure in flexible packaging

Automated Control Systems

All processes are monitored by automated control systems that ensure consistent quality and detect anomalies in real time.

In-House Testing Laboratory

Our Graphic Design Laboratory

Our in-house graphic laboratory is equipped with advanced technologies, providing a full-service workflow from design to print-ready files.

Services Offered:

  • Graphic design consultancy for flexible packaging
  • Adaptation of existing files to printing specifications
  • Development of new graphics in collaboration with clients
  • High-fidelity digital color proofs
  • Prototyping and sampling for approval

Technologies Used:

  • Professional graphic design software
  • Calibrated color management systems
  • HD printing technology for maximum detail
  • CDI QUARTZ technology for superior definition

In Short (Q&A)

Everything you need to know about Alvapack, at a glance.

Q: What makes Alvapack’s production process exceptional?
A: Alvapack’s quality stems from an advanced production process that combines innovative technologies, rigorous quality controls, and the expertise of a specialized team, ensuring precision, consistency, and high performance at every stage.

Q: How does Alvapack ensure reliability and continuity in production?
A: We maintain a constant stock of 400 tons of raw material, which guarantees reliability, continuous production flow, and on-time deliveries for our customers, even during peak demand.

Q: What is Alvapack’s production capacity?
A: Thanks to continuous investment in cutting-edge technologies, we maintain high production volumes while ensuring maximum quality, flexibility, and efficiency.

Q: What types of machinery and technology are used?
A: We employ flexographic printing machines, lamination lines, precision slitters, and perforating machines, all integrated with HD printing technology, CDI QUARTZ imaging, and automated control systems to deliver precise, high-quality flexible packaging.

Q: What role does technology play in production?
A: Technologies like HD printing, CDI QUARTZ, and automated control systems ensure consistent print quality, high-resolution graphics, and efficient monitoring. Sustainability-focused technologies such as ALVA RPP PYROLYSIS and ALVA BIO-CIRCULAR FILM further enhance the eco-performance of our products.

Q: Why should customers choose Alvapack?
A: Customers choose Alvapack because we combine technical excellence, innovative technologies, sustainability, and production reliability, delivering flexible packaging solutions that preserve product quality and ensure timely deliveries.

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