the italian edge: technology for excellence

T H E I TA L I A N EDGE

TECHNOLOGY FOR EXCELLENCE

Published By:

I T A L I A N T R A D E COM M I S S I O NCHICAGO OFFICE

401 North Michigan AvenueSuite 3030

Chicago, IL 60611

291305.P001-004:Excellence 8/27/09 6:34 PM

2 T H E I T A L I A N E D G E

Invoking the textile and automotiveindustries of Italy, our cover reflectssome of the many facets of itstechnological excellence. Drawingon inimitable Italian fabrics, thewrapping frames a monochromemetallic background inspired byartistMichelangelo Pistoletto’s workwith a printed detail fromFiat's new500 model. As a quintessentialsymbol of Italian ingenuity, Fiat’stechnology was able to helpChrysler, an historical icon ofAmerica's traditions. We haveselected an environmentally-soundmaterial for the binding.

ON THE COVER

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3TECHNOLOGY FOR EXCELLENCE

T H E I T A L I A N E D G ETEC

HNOLO

GYFO

REXC

ELLENCE

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4

This publication is a project by:The Italian Trade Commission – ICE

Chicago Project Coordinator:Pasquale Bova

Editorial:Nova Lab / Il Sole 24 Ore

Graphic Design:Pier Paolo Bozzano

Printed by:Meridian Printing

All rights reserved

Rome Project Coordinator:Matteo Picariello

Chicago Team:Josephine Albanese,

Corrado Cipollini, Bart Pascoli,Kate Roberts

and Christopher Thompson

Production:EMCMedia / Il Sole 24 Ore

Juliet Faber

Translation Team:Brigitte Auteri, Giorgio Di

Berto, Susan Chandler, RuariMcCallion, Miron Stefan

and John Venerella

CREDITS

© 2009 The Italian Trade Commission

The editorial content of "The Italian Edge: Technology for Excellence"(including, without limitation, all information pertaining tothe persons and organizations referenced therein, financialprojections, analysis, research, conclusions and opinions) hasbeen prepared by and represents the sole and exclusive workproduct, representations, views, conclusions and opinions ofNova Lab/Il Sole 24 Ore. The Italian Trade Commissiondisclaims and shall not be held responsible for anyinaccuracies, quotations, citations or statements of fact madeby Nova Lab/II Sole 24 Ore. You should not rely on "TheItalian Edge: Technology for Excellence" for investment, tax or businessplanning advice.

The “The Italian Edge: Technology for Excellence” is not produced,commissioned, sponsored or endorsed by any of the personsor entities referenced or depicted therein.

All rights reserved. "The Italian Edge: Technology for Excellence" is subject to,without limitation, the copyright laws of the United States, the BerneConvention for the Protection of Literary and Artistic Works, the WorldIntellectual Property Organization Copyright Treaty and the UniversalCopyright Convention.

No part of this publication may be reproduced, stored in a retrieval system, ortransmitted, in whole or in part, in any form or by any means, now known orhereinafter conceived, electronic, mechanical, photocopying, recording, orotherwise, without the prior written permission of the Italian Trade Commission.


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Nouriel Roubini, Professor of Economicsat New York University, is on the 2009Time magazine list of the 100 mostinfluential people of the world. “Hewarned that there was a monstrousbubble in the housing market and thatthe bursting of that bubble would causemuch of the financial system to collapse,”said the magazine. (AP Photo/MarkLennihan)

291305.P005-033.CRX:291305.P005-033 9/2/09 9:31 PM

TECHNOLOGY FOR EXCELLENCE 11

It has always surprised me how the world has underestimated theingenuity of Italian advanced industrial technology. And yet Italy has beenable to compete and succeed in a worldwide market thanks to theinnovations of its small-to-medium sized companies – only 25% of thoseemployed in the manufacturing sectors work in companies with over 250employees – and to the extraordinary technological advances, flexibilityand creativity of its machine-tool producers and entrepreneurs. Italy doesnot have many large, multinational enterprises. We know about Fiat,especially now, in light of its recent intervention to support Chrysler, againthrough its exclusive and advanced small car manufacturing technology.We are also familiar with its oil company, Eni, and the utility, Enel. But theindustrial texture of Italy has thrived on its mid-sized firms’ winningstrategy of competing at the top end of small niche markets. By makingacquisitions of competitors in their field, they have in many casesconsolidated their market position to become world leaders. Occupyingthe top positions has created economies of scale and freed up resources forresearch to keep competition at bay.This industrial model has an interesting ripple effect: the fragmentationof small-to-medium sized companies translates into a systemic flexibility forItaly as a whole that protects it on the downside when change arrives. Inother words, both experiments and adjustments will never be too costly. Ifind the Italian Trade Commission’s initiative to showcase these companies(and often, the families behind them) a valuable way to endorse thetradition in Italian industry that small is often beautiful, particularly whenit comes to motivation and technological advancement.

FOREWORDNOURIEL ROUBINI

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T H E I T A L I A N E D G E12

Umberto Vattani, President of the ItalianTrade Commission (ICE), has been formany years in the Italian DiplomaticService: twice Secretary General of theMinistry for Foreign Affairs, he hasserved as Ambassador in several countries.He is also President of The VeniceInternational University (VIU) and of theItaly-Japan Foundation.



This publication was developed to highlight some of the success stories ofItalian technology and demonstrate the variety of efforts being made ininnovation and applied research. Both of these factors have beeninstrumental in the development of Italy’s industrial system. Italy’s vocationfor manufacturing is well known, but not everybody has had theopportunity to appreciate the role played by Italy’s industrial machineryand plants, which are leaders in the world.In the first issue of this publication, we take some of the best known“Made in Italy” brands as our point of departure, highlighting how thesesuccesses are not only due to the creativity and ingenuity of our worldfamous craftsmanship, but also to the availability of advanced, flexibletechnologies.Through interviews, photos, and reports, you will discover the small,medium and large enterprises that are the unseen face of many top-sellingproducts, as well as the many “Made in Italy” industries, ranging frommachinery to component manufacturing, from chemistry to electronics.The Italian Trade Commission welcomes the opportunity to promote thecomplex task of mapping out the companies who best exemplify excellencein their fields. We have entrusted it to the expertise of journalists fromItaly’s major financial periodical, and we are grateful to them for havingcarried it out.In the next issues of this publication, we will focus on different sectors,continuing to build this valuable collection of materials and companystories.Besides those who work in related fields of technology—who willcertainly find aspects familiar to them regarding Italy’s extraordinary andmultifaceted nature—we are confident that these publications will appealto the broadest range of readers. Especially students, who willunquestionably discover cues for a better understanding of Italy’s industrialstructure, and who may wish to dedicate themselves to fields likely to offerthem great satisfaction.

PRESENTATIONAMBASSADOR UMBERTO VATTANIPRESIDENT OF THE ITALIAN TRADE COMMISSION - ICE

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14

ithin its borders Italy contains a universe of trades and arts. It is a countryof artisans who give life to the ideas in their head by working with theirhands. Behind “Made in Italy” shoes, or cars, or design, there hides a webof production composed of many smaller traditions. This web is anenormous asset for Italy and is a fundamental part of the country’seconomy. This way of working is characterized by the many clusters of

small and medium-sized companies distributed throughout Italy. It wouldbe a mistake, however, to believe that behind all Italian products there are only

small workshops. The true strength of “Made in Italy” — the thing that gaveinternational recognition to the workmanship and art demonstrated by Master

Geppetto, the father of living puppet Pinocchio—is technology. Manual craftsmanshiphas become integrated with high technology equipment to allow customization in style, andgive the same, if not better, precision in the process of manufacturing. Constant emphasis onresearch allows today’s Italian industries to rely on highly sophisticated machinery andproduction means.It is from this fertile terrain that the technical knowledge and potential behind “Made inItaly” flow and is the reason it is known globally as a mark of superior quality. It is thanks tothe manufacturing hotbeds and small to medium enterprises that, despite the recession, Italyhas retained its prominent position in the internationalarena. According to the European Commission,clusters (defined as highly specialized productionsystems that are largely unique in a givengeographical area) in Italy have maintained astrong position as they create jobs, increaseexport levels, and foster innovation.Italian clusters provide an interestingproduction mix: they do not concentrateonly on machine building, as inGermany, and they do not focusexclusively on traditional goods, as inSpain. Here are a few examples toillustrate the efficiency of “Made in Italy”

W

T H E I T A L I A N E D G E

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On the left, the Fiat 500 attractsnumerous visitors during the firstpublic weekend of the 79th GenevaInternational Motor Show inGeneva, Switzerland, March 8,2009 (AP Photo/Keystone,Salvatore Di Nolfi)

Above, detail of the vehicle’soffside fender

15

products.In the automotive sector,

the most important cluster inEurope is in Stuttgart, Germany

(136,353 employees), followed immediatelyby the one in Piedmont (85,915 employees). Inthe field of mechatronics, however, Italy is theleader in Europe: the most important area is inLombardy (90,283 employees), followed byStuttgart (82,471), Emilia-Romagna (60,723), andthe Veneto (43,931). “The entire electroniccomponents industry is extremely well-placedand very strong,” confirms Angelo Airaghi,president of the R&D Commission of ANIE(the Italian Federation of Electrotechnicaland Electronic Industries). The

components industry is anetwork of suppliers

INTRODUCTIONTHE TECHNOLOGYBEHIND“MADE IN ITALY”

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16

and subcontractors who work oncommission and who invest continually ininnovation. This is witnessed by cases likeComerson, the company that has developedsoftware capable of reconstructing details ofimages captured by video surveillanceequipment. Another example is MagnetiMarelli, which has pursued numerous linesof research on vehicle telematics products inthe automotive field. The outcomes of thisresearch have had applications for brakes,lights, and, most recently, for power steering.Furthermore, Lombardy also ranks top inEurope by number of employees (166,590) inthe machine building sector. Themetalworking and mechanical engineeringindustry is another interesting example: the232,000 companies involved represent 4.5%of all the businesses in Italy, but account for7.6% of Italy’s economy. These figures onlypartially reflect the constant work beingcarried out by thousands of engineers andtechnicians who daily try to adapt newtechnologies to the diverse production needsof Italian companies. According toinformation from ISTAT (National Instituteof Statistics), in Italy there are 38 mechanicalindustry districts, or areas in which “acommunity of people and a population ofindustrial companies are mutuallyintegrated.” Each is in service to the other;each exists as a function of the other.Mechanical industry districts are locatedmainly in the northwestern (17) andnortheastern (16) areas of the country. Thesedistricts owe their vitality to the close tiesthey have developed with other largeproduction sectors in Italy, such as theautomotive and faucet industries.We shouldalso note the significant contribution frombuilders of machines and materials forfoundries made through export. This sectorof the Italian mechanical industry,represented by Amafond, earns 70% of itsprofits from foreign sales – one of the

Above: A decorated area within theheadquarters of Bisazza in Vicenza

Below: A Piaggio Vespa

highest percentages compared to otherdivisions of the machine building industry.Yet it is made up of only 84 companies, witharound 8,000 employees.The data relating to these companies exportfigures attest to the quality of Italy’sproduction system. They also showcase howmuch value the Italian sector has contributedon an international scale. But even beyondthis, they underline the importance ofcraftsmanship as the central element in whatit means to be Italian, harmoniouslyrepresenting a culture of sustainable industrybased on local specialism. Through all of thisruns one common theme: the capacity fortechnological innovation.

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17

heza

Ingenuity and creativity areshown in a creation by fashiondesigner Giorgio Armani (AP

Photo/Thibault Camus)and in Artemide’s installation

at Bicocca (below)

Near Right: Interior designMuri by Marazzi Group

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181.1

he “Made in Italy”phenomenonowes itsgood fortunechieflyto mechanics, evenmore than roboticsor electronics. Overthe years, the mostcomplex theoriesfrom physics and

mathematics have been used inservice of Italian craftsmanship,leading to the creation ofsophisticated instruments formanufacturing. By definition,machine tools are designed to aidthe handwork of any trade; assuch, they have enabled bothsmall-scale entrepreneurs andhigh-profile designers to giveshape and body to their ideas,bringing them to life on anindustrial scale. The quality ofthe finalobject,whethera shoeora piece of high-end furniture, iscentral to the Italian productionsystem. The little workshop ofMasterGeppettohas evolved intothe large commercial facilityfound in the provinces, wheretechnology in the hands ofcreative minds provides forcontinual improvement in productperformance.

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19

The machinefor bending tubes

From the shoeto the lamp:The uses and traditionsof tools

Life saver: Equipmentthat tests dialysis pumps

The leading 400

The machine that wearsshoes

Four wheels thatnever need towing

The machine thatproduces partsfor the Fiat 500

THE STORIESELICA

MACHINES TO EXCEL

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o make a faucet, for example, you need brass –but to cut brass to size, you need a laser cutter;and to work metals well, you need constantinnovation. Such innovation has led to thedevelopment of thousands of types of faucetsand valves such as plug cocks, screw taps, needlevalves, single-lever mixer faucets, and gatevalves. The technical characteristics of these

products, as well as the multitude of their aestheticvariations, require constantly advancing technology.Consider, for instance, a tube-bending machine; its solepurpose is to shape metal into functional forms, but the

TTHEMACHINE FOR

Crippa Machines’ exhibitat the International Fair,Milan, 1959Far Right: Aerospace partscompany Aermacchi usesCrippa technologyfor aircraft systems

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slight nuances of its design has made Italian faucetryrenowned throughout the world. An enclave withinthe Valsesia district of Piedmont, together with a smallarea near Lumezzane (outside Brescia), were amongthe first worldwide production centers for valvesand faucets. They have turned Italy into a majorinternational producer of brass bars with ayearly output of over 600,000 metric tons.This is all well known at Crippa S.p.A., anenterprise in the Como Province that has

been developing and producingmachines for bending and craftingmetal tubes since 1948. Its client listin the decor field boasts the largestcompanies in Italian design. Italso counts among its customersbig names in the heatingbusiness, such as Riello andCarrier. Among the first in Italyto produce tube-bendingmachines, Crippa hascontinually invested ininnovative technologies,culminating in the developmentof the world’s first electric tube-bender, which today serves as thequality standard worldwide.In 2004, Crippa began securingsubstantial contracts in the heating,automotive, and furnishing sectorsto develop integrated work cells. Ateam dedicated to the design ofcomplex installations works ondeveloping this category of product,including industrial robots andmachines for bending or profiling

tubes. “Rather than usingindividual machines and

Italy’s sophisticated tube-bending machinery hasadvanced the country’s international reputation asa premier developer of customized valves andfaucets.Left : Crippa’s Six Cylinder Tube CollectorTop Right : Milling Machine Tubes by Crippa

BENDING TUBES

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manual operators, today’s work cells operate through the simultaneous use of multiplemachines with different functions,” explains Aurelio Crippa, the company’s president. “Theseare integrated to produce complex pieces in continuous cycles, achieving economies at aremarkable scale.”Crippa’s primary sector remains the automotive field. Among its important“Made in Italy” clients are the Fiat Group, Brembo, Alenia, and the Marina Militare (Italian Navy).The company recently provided Agusta with an electric five-axis tube-bending machine and atable for taking laser measurements of the bent tubes. In contrast, Aermacchi uses Crippa’sequipment to produce the ultralight MB 339 aircraft, which is used for training and combatby the acrobatic squadron of the AeronauticaMilitare (Italian Air Force). The company presentlyemploys about 80 people and has a worldwide network of partners. For several years, Crippahas worked with the Polytechnic University of Milan, registering patents for around 10 of theinventions developed. Its technological department, comprising 15 units responsible forresearch and development, receives an investment of between 4 and 5% of annual sales.

AgustaAerospace’sIntegratedDynamicSystem

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n all their variations, machine tools are the realworkhorses of the production process. Lathes,presses, lasers, robots, and machines for automation:these are the instruments that mold and fashion“Made in Italy” products. They are the high-techdevices that allow the Italian faucet, lamp orautomobile to compete on the world market and givethem an edge in specialized markets and productniches. Research has long been central to the field ofmechanics–engineering and physics–but alsoelectronics, automation, and numerical control.

“It is only through our companies’ continual scientific progress thatwe still succeed in competing on a global scale,” says GiancarloLosma, president of UCIMU–Sistemi per Produrre (theAssociation of Italian Manufacturers of Machine Tools, Robots,Automation Systems and Ancillary Products).This progress is the result of significant investments, years ofresearch and interrelated areas of expertise; the three elements thatfind synthesis in various, often small, private laboratories throughoutthe country. In addition, the Italian mechanical industry hasundertaken numerous cooperative ventures with research institutes.Synergies have been created with the Italian academic world but alsowith major US and Swiss educational institutions.Examples of successful Italian companies—those offering hightechnological standards—are many. For instance, UCIMUpresident’s eponymous company, Losma, in Curno (province of

I

FROMTHE SHOE TOTHE LAMP:THEUSESANDTRADITIONSOFTOOLS

Bergamo), operates in the environmental protection sector,designing and producing systems that treat air and cool fluids formachine tools. As such, it is one of the few European companiesthat makes machines with two lines for purification (one for air andanother for cooling fluids), which reduces polluting emissions. ButLosma is just one example. The innovations offered by Italianmachine tools are often hidden within a wide variety of productionfields. There are even some market niches where Italian machinetools can truly boast a leadership position, including the aerospaceindustry, the production of prosthetics and medical products, andeven wind farms. Giancarlo Losma explains, “The majority of bladesand wind turbine towers installed in Europe were worked on bymachines produced in the city of Varese or the Veneto region, whilebehind American helicopters, there is a Milan-based company.”

Machine tools: theworkhorses of pro-ductivity. Tradi-tional automotivesystems areadapted by Italianmechanics for ap-plication in othersectors such asmedical products.Left: Losma’semissions-reducingself-purificationsystem treats airand fluids for ma-chine tools

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24

asmec supplies itsclients with test benchequipment, productionlines for automotiveinjectors, and pumpsfor power steering orclutches. Among itsclients we find namessuch as Magneti

Marelli, Fiat, TRW, and Marzocchi Pompe.Yet the automotive sector is only onesegment served by this company based inBari (Puglia region). It has expanded, overthe past few years especially, into thepharmaceutical industry – with excellentresults; the sector already accounts for 10%of the company’s business. Majorinternational players in the healthcaresector, such as Merck Serono S.p.A., useMasmec’s automated systems to assembleand test pharmaceutical dosing machines.A visual control system, deploying videocameras throughout the productionchain, is used for consistency andprecision control. Within the same field,the company’s equipment is used toinspect dialysis machines, focusing on thepump system. Its expertise also extends tothe biomedical field, where it hasdeveloped a system for molecular analysis

MLIFE SAVER: EQUIPMENT

Automotive Robotics: Serving the Biomedical Sector.Pictured: Masmec’s robotic system for DNA diagnosis. Thecompany partners with leading European research centers

specializing in the study of mechatronics

291305.P005-033.CRX:291305.P005-033 9/8/09 11:25 AM

25

THAT TESTS DIALYSIS PUMPS

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Healthcare giants likeMerck rely on Masmec’sretooled automotive systemsfor pharmaceutical usagesuch as robotic systems forbiopsies

of DNA and a robotic system for biopsies and thermal ablation ofpulmonary tumors.Over time, the company has expanded and consolidated its areas ofexpertise. Today it has more than 100 employees, 80% of whomeither have degrees or are specialized technicians overseeing theproduction process, from the design phase, through softwaredevelopment to installation. Since its inception, Masmec hasinvested continually in research and development, typicallycommitting 15% of annual sales to its R&D unit, where some 20people work. It presently studies innovative technologies that haveapplications for both the automotive sector and the biotech field.The progress also is due, in part, to key scientific partnerships withuniversity centers like those in Glasgow, Lisbon, and Stockholm, allof which host leading-edge laboratories in the field of mechatronics,the synergistic combination of precision mechanical engineering,control engineering, systems design, and computer engineering.Research focuses mainly on the opportunities afforded by precisionmechanics with the goal of developing systems that guaranteeperformance excellence, a high degree of flexibility and the abilityto analyze errors.

291305.P005-033.CRX:291305.P005-033 9/2/09 9:59 PM


The Italian machine tool industry has always occupied a top position inits worldwide market sector. It currently consists of 400 companies andemploys more than 33,000 people, with sales of about 6 billion Euros. Theindustry collectively exports more than half its products and ranks fourthin the world for production and third for exports.The UCIMU-Sistemi per Produrre Studies Department’s forecast for2008 highlighted a 5% increase in production, compared to the previousyear, bringing the total to 6.110 billion Euros. This increase was largely dueto the strong level of exports, which reached a total of 3.320 billion Euros,up 7% from the previous year.The machine tool sector consists of a few large companies that aresurrounded by a constellation of smaller firms, 78% of which have fewerthan 100 employees. However, it is the larger, more structured companies(the remaining 22%) that really drive production and exports. Like themanufacturing industry they serve, the firms that make up the machinetool industry are located primarily in northern Italy.

THE LEADING

400

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28

THE MACHINE

n addition to machine tools in the strictest sense, manufacturersalso need systems that detect and set the geometric data that enablea machine to operate automatically. With the use of mechatronics,for example, it is possible to reproduce a foot to model a virtual shoeor to set the profile of thewings for a civilian aircraft in such awayas to facilitate mass production. Founded in Meda (near Milan) in1983, Elbo Controlli makes this type of system its business.“We are dealing with preset systems that allow the operator to set

the initial variables before the machine starts working,” salesdirector RobertoMoriondo explains. “The mechatronics base receivesa video input from a sort of television camera that is used for

processing the geometric information, the angular makeup. Compared to manualsettings, the automated settings increase speed and accuracy as well as reducingboth the probability and margin of error. Repeatability and reproducibility arekey.”

I

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29

THATWEARS SHOES

Elbo Controlli’s patented measuringsystem integrates intelligence thatspans mechanics, optics, electronicsand computer science. It functionsby checking values that aid inevaluating the precision andparameters of machine toolproductivityBottom: Hand Wheel Machine byElbo Controlli

Elbo Controlli already has registered three patents and is the owner ofa measuring system developed through the work of their researchers anda number of external scientists. It is capable of integrating research resultsfrom four fundamental disciplines: mechanics, optics, electronics, andcomputer science.“Our strong point,” says Moriondo, “is the use of unconventional graniticmaterials with low thermal drift. This allows us to maintain the initialgeometric layout by impeding expansion due to frequent thermalexcursion. In this way, the material does not overheat and margins of errorare reduced. Over time, in contrast, a machine that is subject to thermaldrift will alter its values of geometric compensation and so requirefrequent updating of its parameters.”The Meda-based company furnished aviation firm Avio S.p.A. (Turin)

with a special package; a project designed in collaboration with VegaInternational (Turin) and Nikken Kosakusho ( Japan), a retailer of tool holders.The pulling force meter (PFM) devised by Elbo Controlli allowsmeasurement of the “pull” strength of the various clamping componentsof the tool holders, guaranteeing precision in the modeling of the variouscomponents that make up Avio’s airplanes. Elbo Controlli also countsamong its clients Brescia’s Lonati S.p.A., a world leader in machines for theproduction of stockings. It has 650 employees and more than 8,000machines installed worldwide. This Lombardy company purchased twoAnkh tool-presetting machines, which combine user-friendliness withhigh technology. Toè in Conegliano (Treviso province) purchased ElboControlli’s Khyan tool-presetting machine to install in its plant. Toè has30 years’ experience in tool grinding and the production of tools for

mechanics and woodworking. It also produces micro-tools for eyewear.Elbo Controlli is recognized by STANIMUC (STANdard perl’Industria Manifatturiera-Utilizzatori e Costruttori), the Italianorganization dealing with the elaboration, promotion, and adoption oftechnical standards relating to the machine tool sector and productionsystems. This certification is worthy of note, even though there is not yetany internationally accepted standard for this class of machine. Salesdirector Moriondo concludes that, “In the future, Elbo Controlli willconcentrate on making the data processed by the machine increasinglyintelligible. The measurement systems check the concentricity orperpendicularity values, and then, in a second phase, a human-machineinterface provides for a graphic representation of this data in the form ofcurves. By interpreting these, we can estimate the precision of the machineitself.”

291305.P005-033.CRX:291305.P005-033 9/2/09 10:00 PM

30

FOUR WHEELS THAT

291305.P001-033:291305.P001-033 8/27/09 6:15 PM

31

NEVER NEED TOWING

Alfa Romeo, an Italianicon. Italian machine toolmanufacurers are renownedfor their prowess incustomizing machines tosuit end users. In thepicture is an 8CCompetizione

early half of allmachine toolproducers oper-ate within theautomotive field,as suppliers orsubcontractorsto large manu-facturers of au-

tomobiles. As a result, they arefeeling the effects of the eco-nomic crisis even more thanthose in other sectors: rivalry isstrong and competition is toughin the international market. Thesuccess of Italian machine toolmakers - distinguished leaders inthe shaping of metals - is closelytied to the history of entrepre-neurialism in northern Italy.“It comes down to a matter ofindustrial tradition,” says thepresident of UCIMU. “The excel-lence of our machine toolinghas been fueled by the develop-ment of the automotive industryand, consequently, of industrieslinked to the production of ve-hicle bodies.” Each manufac-turer, like Alfa Romeo, Fiat andPiaggio, to name but a few, re-quires custom components andmachinery for various needs. Asa result, the builders, suppliers,

N

291305.P005-033.CRX:291305.P005-033 9/2/09 10:31 PM


and subcontractors learned to adapt over time. Just as in the auto-motive industry, other major sectors of “Made in Italy,” includingfaucetry, textiles, housewares, and furnishings, have pushed Italianbusinesses to increase customization. The working of metals, as wellas of other materials, inevitably had to become more precise andelaborate in order to meet increasingly complex requests.Soaring technological standards, reliability, creativity, and a highdegree of customization are characteristics that today distinguishthe Italian machine tools industry, both at home and abroad. In con-trast with foreign competitors, Italian manufacturers are known fortheir meticulous attention to the requirements of end-users, forwhom they design entirely custom-tailored solutions.The president of UCIMU is convinced this is the future. Italiancompanies in this sector, “no longer turn to the mass productionmarket,” he says. The key concept is quality, an objective that goeshand-in-hand with flexibility. Looking to the future, the new frontieris populated with eco-compatible machines that provide guaranteedenergy savings.

Abarth cars at the GenevaAuto Show, in 1956

The future of the machine tool industrylies in the eco-compatible machines that

feature guaranteed energy savings

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33

291305.P005-033.CRX:291305.P005-033 9/2/09 10:06 PM


iat and Ferrari, as seen through theeyes of the Vaccai & Bosi Group, aretwo of the great names in theItalian automotive industry. Theyare also linked through their use ofthe same metal cutting machinery.In fact, the supplier andsubcontractor for both of these

important “Made in Italy” companies is PrimaIndustrie S.p.A., located in Collegno (province ofTurin).The structural parts that provide stability andrigidity to the chassis in modern cars, and whichprotect passengers in collisions, are increasinglyconstructed of hot-formed, high-resistance steel.Similar in certain respects to the “blue steel”traditionally used in springs and shocks, thismaterial combines strong mechanical propertieswith ease of machining, which is made possiblethrough the use of specialized laser cutters. Withthis in mind, Prima Industrie designed the trimcutting for the new Fiat 500’s “B-pillar” whichincludes support for the roof and the framingsystem to strengthen the doors. It also serves as apassive element of added safety in the case of sidecollisions. In order to manufacture the pillar,Prima Industrie uses its newest three-dimensionallaser cutting system, the Rapido Evoluzione, which

boasts faster cuts along linear axes, allowing for adrastic reduction of production time and costs.The continuing force behind the creative processof research and development by Prima Industrieis the industrial environment in which thebusiness operates. It is located in the Turin area,Italy’s automobile manufacturing capital, wheredesigners like Pininfarina, Giugiaro, Bertone, andmany more got started. “In creating newprototypes, company leaders focus constantly oninnovation,” explains Domenico Appendino,Prima Industrie’s marketing director.Working with materials that are increasingly

lighter and more resistant requires thedevelopment of new technologies. This is thestarting principle for the Prima Industrie team: ituses machines that allow it to model thinner platesthrough the use of three-dimensional laser cutting.“We invented a robot to perform this type ofcutting, which guarantees a greater degree offlexibility. Initially, it was used only in theaerospace industry,” says the marketing director,“Today, however, our machines are used not onlyin the automotive field, but even by artists whowant to work materials in a way that involvespersonalizing the specifications of the incisionswithout using dies. Hence, a part of a lamp or of atable might come out of one of our machines.”

FTHE MACHINE THAT PRODUCES



THE PARTS FOR THE FIAT 500

Prima’s Optimo CuttingMachine. The newestthree-dimensional lasercutting system allows for fastercuts which slash productiontimes and lower costs


36

Art,lighting,andautomotive

technologyareallincluded

underElica’stechnically

engineered

andinnovatively

designedrangehoods.BasedinFabriano

(theMarche

region),theindustrialgroup

currentlyboastsover

60patentsand

some25registeredtrademarks-figuresthat

bearwitnesstoElica’senormoustechnologicalsuccess.

Kitchen Range Hoods


37

E L I C A

THESTORIES



Elica is the company at the head of Elica Group,which makes range hoods for domestic use. It is theworld’s foremost producer of kitchen range vent hoodsand the market leader in terms of number of unitssold. Elica Group also prides itself on being one ofEurope’s leaders in the field of electric motors fordomestic furnaces.Elicahas been listed in the STAR (high performance

equities) segment of the Italian stock exchange sinceNovember 2006. Seventy-five percent of the company’sbusiness consists of supplying other organizations,mainly well-known household brands such asWhirlpool, Electrolux, Indesit, Fagor, Bosch-Siemens, GeneralElectric, and Mabe. The remaining 25% comprises thecompany’s production directed toward the public, asegment in which Elica distinguishes itself.“We engage in some external collaboration and use

selected suppliers who utilize advanced technologiesand innovative materials,” said Elica Group CEOAndrea Sasso. “Our partnerships also involve theMarche Polytechnic University and the PolytechnicUniversity of Milan. Furthermore, in working assuppliers we have the opportunity to work with thelargest research centers of multinational companies,where we strive to adapt our innovative technologies totheir needs.”

The Satellite Orbiting Around Elica

Previous page: Elica’s Ola : arange hood product that creates

elegance in the kitchenBottom Left : Star by Elica, adual-purpose lighting and air

purification productBottom Right : Vogue Hood in

Leather



The brand was created in 1970 by Ermanno Casoli, a highlyenterprising Italian veterinarian who one day conceived of and built auseful kitchen product, which turned out to be a range hood. Shortlythereafter, he presented his project to Philips and obtained his firstcontract. This was the beginning of gradual but steady growth. Elicabrought the range hood into Italian households and the brand spreadthroughout Europe. By 1978,Elicahad 130 employees and annual salesof 3.5 billion Italian lire. Today his son, Francesco Casoli, who joinedthe business when he was just 18, heads the company. With artisticvision, supported by a strong commercial background, Francesco hascreated a wave of innovation. In 1999, he decided to launch a productline with the collaboration of David Lewis, a renowned internationaldesigner.“Today we have an internal team, the Elica Design Team, which has

become fundamental to the company’s activity,” the CEO explains. “Anice suit, however, is not enough unless it’s backed by excellenttechnology.”In the late 1990s, Elica began pursuing a strategy of acquisitions and

partnerships that remains active today. It was able to extend its activitiesinto complementary sectors through the acquisition of companiesranging from Fime S.p.A., which produces motors and engines, to thevery recent takeover of Gutmann, a German maker of high-end rangehoods. Currently, the Group has eight branches worldwide, includinglocations in Poland, Mexico, and Germany.In March 2008, Elica and Artemide, a world leader in the lighting

sector, closed a major three-year contract focused on the sole objectiveof entering a new market segment with Luxerion, the first line ofmultifunctional products to integrate design, lighting, and airpurification. Artemide takes care of the design, production, andmarketing of the entire line, while Elica provides the technology formoving and purifying air.“In venturing outside our sector,” Sasso states, “wemade the choice of

improving our products by acquiring innovative capabilities andcutting-edge technologies that had previously been tested in differentfields, such as the automotive or lighting sectors, and then adaptingthem to our own needs.”

a

Veterinarian and Inventor

Below: Elica’s Machine LabLeft : Om Hood Special

EditionRight : Elica’s Futura Splash-

board

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40

CHAPTER1.2

he first person to categorize prehistorictimes into four main ages was Danisharcheologist Christian JürgensenThomsen (1788–1865). He proposedhis divisions on the basis of thematerials used to shape common itemsof daily use, naming them the Stone,Copper, Bronze, and Iron Ages, respectively. Ifwe wanted to define our era in terms ofa single material, it would have to bePlastics. Today, with industrialization

and the explosion of mass consumption, plastics such asrubber have become the most commonly used materialsin the majority of objects surrounding us. This includeseverything from the packaging tub for ice cream to thebristles on your toothbrush to fundamental parts of anautomobile body. It is increasingly common to find, atthe source of these products, know-how developed byItalian companies. In many instances, “Made in Italy”machines and devices are involved in the molding ofplastics used by international packaging companies andmajor automobile producers.The companies that build machines and molds forplastics and rubber are united underAssocomaplast (theItalian Plastics and Rubber Processing Machinery andMolds Manufacturers’ Association). They constitute animportant production sector of Italy’s economy, providinghigh-quality manufactured goods that can be tailored tothe needs of an international clientele.Since the 1950s, this important part of Italy’smanufacturing industry has undergone constantevolution. It has now reached a level of technologicalsophistication that results in high productivity and theability to customize machinery to meet vastly differentrequirements. The attention paid to the specific needs ofthe end-user has, as Assocomaplast President Riccardo

Comerio affirms, “pushed forward the implementationof strategies of direct collaboration with the clients,studying together with them the most functionalproduction solutions.”Over many years, the companies that build machinesand molds for plastic products have set new records intechnological innovation. In 1910, a number of Italianplants developed the first compression and transferpresses for the manufacture of electrical accessories madeout of phenol-formaldehyde, one of the first syntheticsubstances. Next, Italy introduced the world’s firstinjection machine with a 5,000-ton closing force. It wasconstructed in the mid-1960s for the manufacture of largecontainers (Italy began production of this type ofmachine in 1940, building upon early Germanexperiments dating back to 1923). The world’s largestthermoforming machine was also built in Italy. It iscapable of processing plates larger than seven meters bythree meters, which are used in the construction ofleisure craft. This kind of device was first produced andmarketed by Italian manufacturers in 1979, a number ofyears before the German competition, and ahead of theAmerican and Japanese by even more.Italian producers have also managed to assert themselveswithin the specific niche of machines and systems for themechanical recycling of thermoplastics and rubber. Afterhaving installed numerous complex systems in Americaand Europe, they saw demand accelerate for this type ofproduct, especially in developing countries where anincrease in the standard of living has been matched by arise in ecological concern. Recycling is a boon from aneconomic point of view. Savings from using recycled,rather than new, materials increase the value of scrapmaterials because they are reinserted into the productionprocess. This advance is a result of the sophisticationachieved by Italian technology.

T291305.P034-063.CRX:Excellence 9/8/09 6:33 PM

41

The machine thatpackages food

The leading 300

The machine thatmolds toothbrushes

THE STORIESARTEMIDE

SHAPING MATERIALSMACHINES FOR PLASTIC


THE MACHINE THAT

PACKAGES FOOD

MB S.p.A. was founded in 1967 in the Brescia area by theBugatti family. From its beginnings, the company hasdistinguished itself with high quality products for moldingplastics. BMB’s business spans two separate markets: onebased on the fast molding of products with very thin walls,which are used in packaging; and the other based on a moretechnical molding process, used in the telecommunicationsand household appliance industries.The list of BMB’s clientele includes highly respected names

such as Piberplast, a leader in the food packaging industry. There are morethan 150 machines in Piberplast plants with the BMB label on them, eachproducing hundreds of ice cream containers every day. These then maketheir way to the plants of well-known European brands such as Cart d’Or,Algida, and Cremeria Motta. BMB machines also are used by Artsana,one of the leading manufacturers of children’s products, cosmetics, andhealthcare accessories. Some of Artsana’s better-known brands includeChicco pacifiers, Prénatal children’s toys, Pic Indolor medical products, andControl condoms.BMB’s client list also includes Candy, Comapsud, and suppliers to otherappliance manufacturers such as Merloni, and Electrolux. BMB’s technicalmolding systems are used to construct not only the internal tubs of thewashing machines but also their front panels and the more visible externalpush buttons.Directly competing with German manufacturers, BMB consists of about200 employees and a highly respected research team. The family-run firmbrings about 400 machines to market yearly, with overall sales hoveringaround 80 million Euros, 60% of which come from exports.

B

42

291305.P034-063.CRX:Excellence 9/3/09 8:53 AM

The Italian plastics and rubber processing machine industry is made up ofslightly fewer than 300 companies. It has a workforce of around 12,500,including those employed by subsidiaries and suppliers, plus about 1,000mold- and die-makers.Italy ranks second worldwide (after Germany) among countries exportingsuch machinery, handling about 12.3% of the total market in 2007. In 2008,however, the effects of the economic crisis definitely became apparent.Although sales contracted, production levels - equivalent to over 4.1 billionEuros annually - remained high, compared with previous periods. Exportsreached 2.6 billion Euros in 2008, which was more than half of totalproduction.It is difficult to make any sort of projection for 2009, given the decline inorders during the second half of 2008. Even with the most optimisticoutlook, any percentage changes for the sector in 2009 will likely carry anegative sign.

THE LEADING

300


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44

THE MACHINE THAT

rom household items to chairs signed by top Italian designers, thereare various internationally known “Made in Italy” brands that useplastic in entirely original ways, thanks to advanced processingtechniques borrowed from other production sectors. The commondenominator among these companies, that whichmakes it all possible,is the machines. Specifically, the injection presses of Negri Bossi, acompany in Cologno Monzese (outside Milan), are essential to givinglife to designers’ artistic concepts. “The design on paper,” explainsNegri Bossi’s sales manager Antonio Rampone, “takes its form thanksto ourmachines through the integration of various innovative materialsand in keeping with increasingly specific profiles.”For the Fratelli Guzzini company, for example, the design and processing

of materials are fundamental. Established in Recanati in 1912, this internationally renownedhousewares brand uses advanced molding techniques and very expensive plastics to createprecise forms. The same goes for Kartell, a leader in industrial design based in Noviglio(Milan province), whose partners include other important designers like Ettore Sottsass andAntonio Citterio. Both companies useNegri Bossimachines.Central to the production process is the selection of the proper profile for the “screw”,which rotates through the heating cylinder to melt the original plastic granules. NegriBossi technicians focus on the plastification phase of raw materials, which occurs duringheating but before they are injected at extreme pressures into the mold. For each type ofmaterial, precise parameters must be defined; otherwise, the plastic might lose thetransparency required by the original product specifications, or worse, it might be burned.This process is based on the chemical and flow characteristics of the materials and variesaccording to the nature of the product being made. “Making an automobile headlight isdifferent from making a chair,” explains Rampone. “If on the one hand there are somebasic universal templates, on the other, for our clients, work on customization is necessary.”

F

Detail of Negri Bossi’sJanus 370 press, a modular

hydraulic hybrid



MOLDS TOOTHBRUSHES

Negri Bossi : Injection Press Factory AtWork. The company has adaptedadvanced processing techniquesborrowed from other production sectors

Negri Bossi machines also are behind Durban’sand Emoform toothbrush brands produced byPonzini, the Italian manufacturer of oral hygieneproducts and cosmetics. For such products, theprecise manipulation of the plastic material iscrucial to guarantee the soft feel of the grip, theflexibility of the toothbrush, the structures of thevarious bristles and even the electrical vibrations.“For Ponzini, we designed a machine with six

separate injectors, to allow for the simultaneousproduction of family packs of four brushes, eachwith a different color grip,” saysNegri Bossi’s salesmanager. The company also does business in theautomotive sector, supplying Fiat with anautomated system for molding the bumpers forthe new Lancia Delta.“The machine was dimensioned and calibratedin collaboration with the automobilemanufacturer and customized on the basis of theoperational layouts,” explains Rampone. “Herewe’re talking about an injection press forthermoplastic molds that can handle up to 3,500tons of closing pressure. Digital-controltechnologies increase the precision andhomogeneity of the final products, besidesallowing for a greater degree of customization onthe design side.” For the Lancia Delta’s bumpermold, Negri Bossi created a new plastificationscrew profile and a special automation systemintegrated into the press.


Anown throughout the world forits philosophy of ”The HumanLight,” Artemide focuses onhumanity’s search for well-being. The true soul of thecompany lies inchromotherapy, the therapeuticuse of light and color. It is

Artemide’s strong commitment to researchthat has enabled it to become a major playerin the market for high-end illumination forresidential and commercial use. Its lamps,modeled from novel materials, are capable ofgenerating a wide range of hues.“Artemide stands, first and foremost, fordesign,” declares production manager AlbertoScotti. “Creativity is our primary innovation.Having said that, we must use advancedtechnologies in order to give life to our ideas.These technologies were often developed inother sectors, like the automotive oraeronautics fields, and then adapted to ourown needs. Our main task consists of seekingto translate the artistic concept into a finishedproduct, using the most advanced moldingtechnologies available on the market.”

KPiquadro HQ, Italy by Artemide, a lighting design company that develops prod-ucts based on the therapeutic use of illumination and color and uses technology to

mold novel materials into lamps



A R T E M I D E

THESTORIES




Left: Nike’s London HQ

Clockwise from Top Right :Interior design of HelvetiaPatria, Switzerland; Sectiondetail of The New York PalaceHotel; Watt 13 Hotel, Milan;Artemide’s CabildoSuspension; Talo Parete light

“Once we receive a sketch from the designer, we thenhave to figure out how to create it,” notes AlbertoScotti. “Doing this often requires materials andinnovative technologies that are not available on themarket.” To be able to give form to the creativefantasies of the large firms that work with it,

Artemide must continue investing in research,borrowing the most advanced technologies in anyand all industrial sectors. Its research, accordingly, isfocused on molding processes that control thebehavior of specific engineering plastics as well asadvanced techniques for manipulating plastics andhigh-tech materials. Another line of research focuseson electronics, developing LEDs and furthercomputerizing management of the product.

Creativity is synonymous with hi-tech



Elastoforming, for example, is a molding techniquedeveloped initially in the aeronautics sector foraluminum aircraft panels. The method uses veryheavy presses to shape the sheet metal on a bed ofrubber rather than a traditional mold. The machinefor elastoforming, supplied to Artemide by aproducer in the Triveneto area (the three regions ofthe Veneto, Trentino-Alto Adige, and Friuli-VeneziaGiulia collectively), allows production of highlyspecific shapes with precise folds and subsections,more than would be possible with normal molds.“This technology is used to give life to Artemide’sCadmo lamp,” explains Scotti. “It was the only wayto model a very particular shape, a sort of totem-likefloor lamp that develops in three dimensions.” It isthe same with hydroforming, another technique usedby Artemide to create their products.“This is a molding technique that uses water,allowing for the manufacture of lamps like the AquaEll, which looks like a sort of elliptical pumpkinwith a corrugated surface,” explains the productionmanager. “In this case, it’s water pressure that shapesthe sheet metal pieces, by pressing them, just as inother methods, against other surfaces.” Thistechnology used for Artemide by a Lombardysupplier was developed initially for militarypurposes, specifically for molding bomb casings.It was the Giacinto Gismondi Research andInnovation Center that developed the software fromwhich theMetamorfosi line was born. These lampscan intelligently manage chromatic gradations,allowing the blending of the primary colors so thatthe user can select the preferred light with a simpleremote control.“This technology has allowed us to make a

significant jump in the quality of our products. Itwas on this product line that we were able to baseour concept of chromotherapy and develop a new

company philosophy focused on ”the human life” inrelation to its well being,” Scotti concludes.“The Human Light,” which has since evolved into“MyWhite Light,” was a groundbreaking inventionthat redefined lighting design in terms of the user’swell-being. The goal is simple and, at the same time,extraordinarily complex: to make lighting capableof improving quality of life by combiningillumination engineering performance and flexibleuse with minimal consumption of natural resources.

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CHAPTER1.3

50

291305.P034-063:Excellence 8/27/09 9:12 PM

ALL-ITALIAN BIOTECH

51

291305.P034-063:Excellence 8/27/09 9:13 PM


Biotechnology has taken a pre-eminent position among Europe’sstrategic priorities. Recognizing this,members of the European Unionhave begun an all-out competition forbiotech development, in some casesencouraged by government incentives.In fact, the number of biotechindustries in Italy has increased by52% since 2001. During the last threeyears, five Italian biotech companies(Gentium, NicOx, BioXell, NewronPharmaceuticals, Cosmo Pharmaceuticals)werelisted on major foreign stockexchanges, while another,MolMed,wasquoted in March 2008 on BorsaItaliana, theMilan-based Italian stockexchange.The data is very promising: 228Italian companies are investing inresearch and development in variousbiotech areas. Almost 5 billion Euros

are generated from the sale of biotechproducts, and the sector grew by 11%in the past year. Investments in theR&D sector totaled about 1.3 billionEuros, an increase of 9% from theprevious year. Italy currently hasabout 26,000 employees working inbiotech, with 6,600 involved inresearch activities.When the biotech industry isbroken down into segments, it is clearthat the predominant focus is onhealthcare, with 168 companiesoperating in that area. These firms arereferred to as the “Red BiotechCompanies.” By comparison, 30companies work in agriculture,animal husbandry, or the veterinary,known as “Green BiotechCompanies.” Another 19 operate inthe industrial or environmental fieldsknown as the “White Biotech



Companies” and 11 are orientedtoward research and development inthe field of bioinformatics.Italy’s biotech industry is earning anincreasingly competitive position inthe global marketplace. Assobiotecdirector Leonardo Vingiani pointsout that, “Until recently, Italy didn’teven show up as a blip on the radarscreen among multinationalpharmaceutical companies, whereastoday Italian research is beginning toassert a unified presence that isrecognizable.” The products andmethods of Italy’s biotech industry areincreasingly showing up in industrysectors, ranging from healthcare toagriculture to environmental clean-up.The number of products undergoingclinical development in thepharmaceutical field continues to

increase. There are 33 products inPhase 1 trials, 35 products in Phase 2,and 16 in Phase 3 (the phase directlyprecedingmarketing). In addition, 63products are in the preclinicaldevelopment phase and 99moleculesare in the discovery phase, indicatinga promising future for the sector.Indeed, the pharmaceutical sector isattracting a significant share ofinvestments. According tocalculations byAssobiotec’s Vingiani,“Between 2006 and 2008, we wentfrom 30 medicinal products to 84, allas a result of Italian research.” Inalmost all of the cases, these productsrepresent advancements intherapeutic areas such ascardiovascular disease and immunesystem disorders. In short, thesediscoveries may significantly improvethe quality of our lives.


1.4

The Italian chemical industry is deeplyintertwined with the success of “Made in Italy.”“We must remember what lies behind theexcellence of many Italian products—from tilesto textiles, from shoes to furniture,”Federchimica president Giorgio Squinziobserves. “It is not only about great designcapacity but also the technological brilliancethat stems, more and more frequently, frominteractions between the hundreds of chemicallaboratories whose products are a testament totheir innovative capacities. In other words, thechemical industry is the turbocharger of ‘Madein Italy’.” In 2008, enterprises in the industryachieved a combined value of about 56.5 billionEuros. The industry can be divided into threegroups: medium-to-large sized companies (23%),small to medium-sized companies (41%), andthe multinationals (36%). The workforcenumbers approximately 123,000 employees(excluding the pharmaceutical sector), of whomone-fifth hold college degrees. Exports amountto 40% of the goods produced (22.5 billionEuros), with specialized chemistry the standoutsector. “The technology of Italy’s chemicalcompanies, which has made Italian productsstrong worldwide competitors, has beenavailable now for some years on the globalmarket,” Squinzi says. “Not only to clients inthe historical markets of Europe and America,but also to emerging economies.”Pharmaceutical groups such as Bracco, ACSDobfar,and Indena have been international for decades.In the textile industry, the recognized names areBozzetto, Lamberti, RadiciGroup, and Sinterama.Among the top-earning companies in Italy areMapei, a leader in the construction business,and M&G Group (Mossi & Ghisolfi), theworld’s second largest producer of PET(polyethylene terephthalate), a polymer resin ofthe polyester family and is used in everythingfrom synthetic containers to beverage bottles.

54


Italian design in thepharmaceutical lab:The taxol molecule –Research andpharmacy

The Mater-Bi niche:Total biodegradability

When bacteria takecare of restoration

How chemistry appliedto the constructionindustry made itsappearanceat Beijing 2008

Chemicals, plastics,and fibers

THE STORIESMAPEI

THE ELEMENTS OF“MADE IN ITALY”

55


ITALIAN DESIGN IN THEPHARMACEUTICAL LAB

he taxol molecule forms thebasis of the first anticancerdrug to exceed $1 billion insales. It was Indena thatsupplied it to Bristol-MyersSquibb. Indena is the worldleader in the identification,development and productionof plant-derived activeingredients for use bypharmaceutical, health

food, and cosmetic companies. The corebusiness of this Milan-based company lies inthe industrial production of moleculeswhich are then often patented by its clients.More recently, Indena has moved beyond

process research and into product research,focusing its studies on patented molecules

for use in anticancer, antimicrobial and antiviral treatment, as well astherapies for the central nervous system. It now takes its discoveries allthe way to Phase I and II clinical studies.“We’ve licensed three molecules in the field of oncology, one of which,

a new taxane derivative, has almost completed Phase II of its clinical trials,”says Indena president Dario Bonacorsi. “There are also other moleculesin the oncology sphere that are currently in the early stages of study,including an antineoplastic (anticancer) vaccine.” Nine percent of totalsales revenues are reinvested into research, resulting in 150 registeredpatents and over 700 published scientific articles.This Milanese company is able to reduce costs and times fordevelopment processes, compared with other pharmaceutical businesses,by limiting their analyses to plants that have been previously identified aspossessing specific characteristics.“We invest in the product’s preclinical and clinical development and have

T



THE TAXOL MOLECULE

Active ingredientsderived from plants

are processed into foodand cosmetic products.

Left to Right : Taxus,Gloriosa, Vitis

significantly reduced the costly screening phases that often turn out tobe ineffective,” Bonacorsi explains. These studies are conducted incollaboration with more than 40 institutes and research centers aroundthe world, including the University of Milan, the “Mario Negri” Institutefor Pharmacological Research, and the National Institute for Tumors.Indena exports 90% of its production. Its research center is located inSettala, outside Milan, where the production process begins with thegrinding process. Solvents are then used to extract a concentrated liquid,which is then purified. The plant where Indena produces its high-potencymolecules (those that provide remarkable therapeutic results even at lowdosages) has a flexible purification system based on chromatographycolumns, with an overall capacity of 18,000 liters.The production phases use cutting-edge equipment provided by Italiancompanies like 3V Cogeim of Bergamo, which is a world leader in the field

of filtration and treatment of waste. Another supplier is Euralpha in nearbyLainate, which specializes in “glove box” sealed handling systems. ComiCondor, a company based in SettimoMilanese (just outsideMilan) suppliesfiltration centrifuges for fine chemical production.Tycon Technoglass of San Donà di Piave (in Venice province) was chosen tofurnish Settala’s glass-lined reactors because of its years of experience inthe production of laboratory reactors, agitation systems and heatexchangers.Indena’s finished product is subjected to a series of analyses that use

cutting-edge technology and instrumentation, such as HPLC (HighPerformance Liquid Chromatography) and gas chromatography. Morethan thirty quality assurance checks are conducted through the entireproduction cycle, all in accordance with the pharmaceutical sector’s strictGMP (Good Manufacturing Practices) norms.

57


lthough the Italian biotech industry might still be small in comparison to those of other countries, such as Germany,the UK, or France, it can nonetheless claim significant ”quality of industry.” This ”quality” is the result of a dense fabricof small and medium-sized businesses that occupy small market niches that are unlikely to attract large enterprises.In many cases, they are high-risk, high-innovation spin-offs that emerged when larger industries decided to abandonavenues of research that were not directly related to their core business. They are highly flexible companies that arecapable of entering the international market in specific production “niches.”In the field of plastics, for example, the Italian biotech industry has established important new milestones. Mater-Bi,the world’s first material to be completely biodegradable, is produced inNovamont Laboratories. It was founded in1990 as a spin-off fromMontedison Group and is located in Novara, Piedmont. This plastic material is exceptional

Biodegradable plastic: Novamont’scups are produced using a corn-basedcompound

THE MATER-BI NICHE:

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58 TH E I T A L I A N E D G E


in that it was developed not out of chemicalprocesses but from the use of biologicalproducts: specifically, corn.“This product is an absolute leaderworldwide; it is even used inagricultural fertilizers,” Vingianisays. Its applications are amongthe most diverse, in keepingwith the opportunities andavailability of the rawmaterial.Italy’s biotech industryfurther displaysexcellence in the fieldof technologyplatforms anddiagnostic biosensors,with companies likeSorin, Diasorin, andXeptagen. AlongsideFrance, Italy hasconsiderable experiencein the production ofadvanced biotechingredients for use in thecosmetics industry. Insidemany products found inpharmacies or perfume shops allaround the world, there arecomponents that were created by thebiotech industry, such as certain isozymes.Italian cosmetics companies that usebiotechnologies in their product developmentinclude Artsana, Cosmint, Mascara Plus, Roeder, Lacma Antipiol,Johnson Diversey, Framesi, Mac Pharma, Gotha Cosmetics, Società Cosmetici, SilvioMora, Intercos, Pidielle, Manetti & Roberts, and Synbiotec.

BiotechnologyLeader Novamont’s

Renewable Product Cycle

TOTAL BIODEGRADABILITY

59


One of the iconic monuments of Rome, theFontana dei Quattro Fiumi (Fountain ofthe Four Rivers by Gian Lorenzo Bernini)in Piazza Navona, was the focus of a two-

year restoration process based onbiotechnology.

On the right, a detail of the PietàRondanini by Michelangelo

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WHEN BACTERIA TAKECAREOF RESTORATION

iotechnologies are being successfully put to use in the relatively new fieldof regeneration. Certain microorganisms have been identified for their bio-calcifying properties – their ability to produce calcium carbonate, the mainingrediant of limestone and marble. These microorganisms can be used tobreak down the corrosive sulfates and nitrates that accumulate on stonemonuments.One of the iconic monuments of Rome, the Fontana dei Quattro Fiumi(Fountain of the Four Rivers by Gian Lorenzo Bernini) in Piazza Navona, wasreturned to Romans and tourists alike after a two-year restoration processbased on biotechnology. The restoration effort was made possible byresearch directed by the Istituto Superiore per la Conservazione ed il

Restauro (Higher Institute of Conservation and Restoration). Its program included biocidetreatments to destroy plant material and photosynthetic microorganisms and to cleansurfaces of pollution deposits and “black crusting.” The treatments carefully removedcalcareous deposits, replastered joints, breaks, and restored lines of discontinuity exposedmetal bindings. Attention then turned to rebuilding of damaged support coverings;treatment of gaps; protection of surfaces; and repairs to damaged water spouts. The overallrestoration cost 662,000 Euros, which was paid for entirely by the Ministero per i Beni e leAttività Culturali (the Italian Ministry for Cultural Assets and Activities).The University of Turin is undertaking research and experimentation in the field of biotechrestoration, with a special focus on the biochemistry of microorganisms and on controllingdeterioration of artwork. The University ofMilan’s Agricultural Department has recentlypatented the cleaning method applied to the city’s cathedral and to Michelangelo’sRondanini Pietà. The patent is registered as MI2006A000776, “Processo di biopulitura disuperfici di manufatti di diversa natura chimica di edifici” (A process of bio-cleaning forman-made structural surfaces of various chemical natures).

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he Biocalce division of the Kerakoll Groupstarted off in chemical laboratories and tookflight in the construction field, just grazingthe world of biotechnology. In this way, theModena-based company has become a worldleader in the application of chemistry to thebuilding construction sector.Biocalce is Europe’s foremost producer of

naturally-derived construction materials foruse in the restoration of historically importantpieces.Kerakollmaterials have made possible

the “natural” conservational recovery of some important Italianarchitectural artifacts, paying due respect to the existing structuresand original materials.At the Royal Palace of Venaria at Venaria Reale (near Turin),inaugurated in October 2008 by UNESCO as a World HeritageSite, the company tested new processing techniques andmaterials

with compositions that match the original. Only materials fromthe Biocalce product range were used for the eco-sustainablerestoration of the structure at Venaria Reale, ranging frommortarsof natural lime to the plasters used to restore the structure. Eventhe fine plaster finishings used for the surface leveling anddecorations came from Biocalce.The all-natural product line recently introduced by Kerakollincludes limemortars, plasters and paints, all of which areWTA-certified. WTA is the Belgium- and Netherlands-basedInternational Association for Science and Technology of BuildingMaintenance and the Preservation of Monuments; Kerakollmakes the only product line approved as a suitable solution forthe preservative restoration of historical buildings andmonuments under the jurisdiction of the Superintendence forArchitectural Assets. The same approach was used in completingthe repairs to the main altar (Altare Maggiore) of Genoa’sCathedral of San Lorenzo and in the summer 2007 restoration of

THOW CHEMISTRY APPLIED TO

MADE ITS APPEARANCE


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THE CONSTRUCTION INDUSTRYAT BEIJING 2008

Milan’s Basilica of Sant’Ambrogio, which reopened the followingSeptember. Kerakoll Group is the world’s leading enterprise forproducts and services for the sustainable construction industry,historic restoration, and interior design. Total sales in 2008approached 335 million Euros, 40% of which came frominternational contracts. The group includes 15 working companiesand nine production plants that have generated over 900 thousandtons of finished products. The Group operates through threebrand divisions:Kerakoll specializes in modern construction andcontemporary architecture; Biocalce focuses on construction ofsustainable buildings and historical restorations; and KerakollDesign is the interior and decorative design division.Kerakoll was established in 1968 at Sassuolo, Modena, which isin the heart of the world’s most important ceramics district. It was

founded on the entrepreneurial initiative of Romano Sghedoni.Gian Luca Sghedoni, son of the founder and winner of the Ernst& Young Entrepreneur of the Year 2008 award for Italy, now headsthe Group. It is run with the support of a managerial staff thatcombines experience and technical expertise with an innovativebut highly controlled approach.“If I believe in something, I will follow through with it to the

end, nomatter what the cost,” Sghedoni has declared, repeatedly.“In order to continue growing, one must know how to anticipatethe future.” This is the philosophy he has used for years and itled all the way to Beijing, where the company contributed to the2008 Olympics by paving Beijing’s landmark National Stadium,known as the “Bird’s Nest.” The commission amounted to 350,000Euros.

Fireworks explode overKerakoll’s "Bird's Nest" duringthe opening ceremony of the2008 Olympics in Beijing

(AP Photo/Bullit Marquez)

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CHEMICALS, PLASTICS,AND FIBERS

adiciGroup is an integrated and diversified group of manufacturingcompanies, with products ranging from chemicals to engineering plas-tics to synthetic yarns used to manufacture everything from clothing toappliances.Located in the province of Bergamo, it employs 3,500 people and fin-ished 2008 with gross sales of 957 million Euros. Fourteen of Radici-Group’s plants are located in Italy and account for 60% of the company’sproduction. The chemical business unit comprises three plants and twotrading companies, which constitute an important upstream elementfor integrating the production chain. In the plastics unit, RadiciGroupspecializes in polyamide- and polyester-based engineering plastics and

offers a full range of services, including manufacturing, quality control, research, and tech-nological support for new developments. With its network of commercial sites and fiveplants strategically located in Italy, Brazil, Germany, and China, RadiciGroup can quicklyand effectively meet the needs of customers around the world.The company has 50 years of experience in synthetic fibers. Modern structures, advancedtechnologies and complete control of production processes enhance precision manufac-turing of top-quality yarns for use in various sectors, such as automotive, clothing, fur-nishings, and contract and residential flooring. Each of its units has received qualitycertifications for its systems areas (ISO 9001, ISO 14001, ISO TS-16949) and products (Tex:Standard 100).A team of 40 people fuels the innovative processes of technology and new product devel-opment. Market demands stimulate collaboration with Italian academia, in basic researchespecially. Over the years, the Group has partnered with the University of Milan, MilanPolytechnic University, and the universities of Bologna, Brescia, and Genoa.RadiciGrouplaboratories have notably patented innovations in the textile industry, such as special ther-moplastic synthetic fibers and a production process for a mixture of cyclohexanone/cyclo-hexanol, chemicals used in the production of nylon.

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he “Low DustTechnology” developed byMapei can reduce 90% ofdust emissions resultingfrom mixing, processing,or using constructionmaterials. Themultinational, Milan-based company’s concernfor the environment iscertified by the ”Green

Innovation” logo, a symbol that guaranteesconformity to international eco-sustainability norms.Ultracoat, for example, is a line of water-based products that protect parquet flooring.The products feature very low emissions ofvolatile organic compounds (VOCs) but areable to offer lasting protection, even forfloors subject to intense traffic.“Flexibility and adaptability have been thedecisive elements of our success: we are worldleaders in the floorings, coatings, andceramics sector,” says Giorgio Squinzi, thesole director of Mapei and president ofFederchimica.Sales revenues in 2008 reached 1.7 billionEuros. Output is divided into 15 productlines that span the entire range ofconstruction needs, from the foundations tothe roof. The company processes 16thousand tons of materials a day and fulfills80% of its orders within 48 hours.Mapei dedicates over 70% of its annualinvestment resources (about 85 millionEuros) to research into eco-sustainableproducts. The majority of its machinery isdeveloped in-house, by its own engineers. It

T

Mapei’s eco-sustaining flooring materials combinelow emissions of volatile organic compounds withdurable protective qualities. The firm’s Ultracoatproducts are water-based protectors for parquet

flooring

Top: Applying Mapei’s Ultramastic product

Right: Mapei’s Kerpoxy Production

BUILDINGCONSTRUCTIONAND INNOVATION

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M A P E I

THESTORIES

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has 10 R&D laboratories employingsome 730 people.Three of the labs are in Italy: inMilan (Mapei S.p.A.); Treviso(Polyglass S.p.A.); andVilladossola, Piedmont (VinavialS.p.A). Seven additional labsaround the world are found inToulouse (Mapei France S.A.);Wiesbaden, Germany (SoproBauchemie GmbH); Sagstua,Norway (Rescon Mapei AS);Laval, Quebec, Canada (MapeiInc.); Deerfield Beach, Florida(Mapei Corp.); Dalton, Georgia(APAC); and Winter Haven,Florida (Polyglass USA, Inc.).The company’s ongoing innovativeefforts require a constant flow ofresources. In 2007, Mapeienhanced its plants that producesealers, water-based emulsions andfluidizers at the Robbiano diMediglia (province of Milan)production site. At its Latina plant,

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Mapei is supported in its research by partners inacademia: Bocconi University in Milan and theNational Research Center are two of theinstitutions that are collaborating on projects

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investments were made for premixand liquids installations.Italian universities provide anetwork of support for thecompany. Mapei is currentlycollaborating on projects with theFederico II University of Naples;the Polytechnic Universities ofMilan and Turin; the Universitiesof Padua and Bologna; BocconiUniversity (Milan); and theNational Research Center.Worldwide, Mapei is made up of

57 associated companies, with 55production plants operating in 24countries on five continents.“We are a global company and theUS market holds great potentialfor us,” says Squinzi. “EasternEurope and the Middle East arestarting to appear over thehorizon. Although they currentlyrepresent just 1% of sales, we expectthat, within 10 to 15 years, Chinaand the Far East will also becomestrategically important.”

NASCAR driver RobbyGordon drives through

turn three duringqualifiers for the

NASCAR Pennsylvania500 auto race in LongPond, Pa., at Pocono

Raceway on August 3,2007 (AP Photo/Carolyn

Kaster)

Mapei is a trademark known to every Italian,not only because of its achievements on theindustrial front, but mostly for Mapei Sport,a division that has propelled it to the forefrontof cycling, motor racing and soccer. Mapeiowns Sassuolo Calcio, an Italian seconddivision league team


CHAPTER2.1

ehind any excellent product there is a technology concealed. Behind a finesuit, a delicious meal, a piece of designer furniture, an elegant shoe, therealways is a machine, a production process, an entrepreneur, an idea. Thisrule holds for everything, and “Made in Italy” is no exception.After WWII, Germany was the undisputed leader in the production ofmachines used to make the best things in life. From textiles to ceramics,from glass to wood, the Germanmanufacturing industry grew to dominateworld markets, restoring the country’s image of efficiency and precision,which is still in place today. Italy, for its part, did not stand idly by, andwithin a few decades had made up for lost time. The worldwide marketfor machinery that produces goods today is valued at approximately 30

billion Euros; Italy and Germany together account for more than 70% of the total.Italy has had series of brilliant performances, achieving absolute leadership positions in variouskey manufacturing sectors such as the production of woodworking machines and foodprocessing equipment. There are many more success stories. Wherever you look, whicheversector you take into consideration, the Italian machine-building industry is always present,competing with Germany, the US, Japan, and fast-rising China for leadership in the field.In 2007, the companies belonging to Federmacchine—Confidustria’s association ofmanufacturers of machinery destined for a variety of production sectors (including ceramics,wood, graphics and paper products, textiles, plastics and rubber, footwear, glass, packaging,automation, and farming equipment)—together generated sales in excess of 37 billion Euros,two-thirds of which derived from exports. The sector for food-processing machinescontributed another 3.5 billion Euros, of which 2.2 billion derived from exports.No industrial system can produce consumer goods over a long period of time withoutdeveloping excellence in production technologies. This is happening in China today and ithappened years ago in Italy. Over the course of a few decades Italy’s large production districtsfrom Sassuolo to Parma witnessed the birth and development of companies that provideconsumer goods manufacturers with evermore sophisticated technologies and productionmodels. These innovations were quickly exported, earning Italy an international reputation forexcellence. Sometimes it was the client who requested a machine to help improve his product,stimulating the creativity of the supplier. Other times it was the supplier who proposed a newidea. Still other times an employee from a manufacturing company started his own business,perhaps along with a colleague, transforming a technological insight into a business that couldbe passed down through the family. These are processes that have repeated thousands of timesover the course of recent decades, changing the face of Italy’s image worldwide, its economicstructure, and the well being of its citizens.

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GlassThe aesthetics andenergy of a material

Ceramics and marbleWorkmanship of thepast, techniques of thepresent

FootwearItaly, the world player

TextilesThe history, thechallenges, andglobalization

FoodSecrets from the landof good food

WoodNew generation,ancient origins

THE STORIES

COTONIFICIO ALBINI

ACQUA DI PARMA

LORO PIANA

VIBRAM

FERRAGAMO

NEXT TECHNOLOGYTECNOTESSILE

ILLYCAFFÈ

DONNAFUGATA

ARNALDO CAPRAIMACHINES THATMOLD BEAUTY




THE AESTHETICS ANDENERGYOF A MATERIAL

ne of the must-see attractions foranyone visiting Italy’s art cities is theisland ofMurano. Some of the world’smost cherished glasswork comes fromthis island in the lagoon of Venice.But Murano is also the tip of thediamond for an industry thatrepresents one of Italy’s topachievements in the world market.The processing of float glass, thekind used in building construction,

home furnishings, and the automotive industry, takes place in twophases. The first is the production of sheets of glass. Here Italystepped down some years ago from its role as a primary supplier—there are very few companies operating in this phase of the process,and most are not Italian. Even so, firms such asManfredoniaVetrohave broadened and globalized their activities.But in the second phase of production, Italian machines—thosefor grinding, producing double-pane and safety glass, along withthose for silvering mirrors—hold the position of absoluteleadership, partly due to the fact that this type of production isperfectly suited to the fragmented structure of Italian companies.The same holds true for machines used for grinding lenses andprecision optics. “If any company, anywhere in the world, has theintention of elaborating glass in an expert manner, they cannotoverlook Italian machinery,” explains Renata Gaffo, director ofGIMAV, the Association of Italian Manufacturers of Machinery,Equipment and Special Products for Glass Processing. “Nor can weforget the great attention today’s society pays to energy savings andenvironmental protection. Photovoltaic panels and solar thermalenergy cannot do without glass and mirrors.”In 2007, sales by Italian manufacturers of glass-processingmachinery totaled almost 1.4 billion Euros with more than 73%deriving from exports.There are many Italian companies active in this sector. Amongthese, one of the most prominent internationally is Fenzi S.p.A.,located in Tribiano (province of Milan). After its startup in 1941 asa small factory, this company increasingly focused on the highly

specialized sphere of chemical products used for the second phaseof float glass processing. It ended 2007 with sales of more than 200million Euros.Italy’s technological leadership is also universally recognized in the

other major branch of this sector: the hot processing of glass whereall production phases are performed without letting the glass cool.The production of artistic handmade pieces is one of the morevisible applications of this technique, but there are others that playa fundamental role in the production of many consumer goods weuse daily. Not everybody knows, for example, that an importantindustrial process involved in creating nearly all the world’sstemware--the welding of the base to the stem--is carried out usinghigh-tech machines from the Italian company Ocmi. The samecompany also holds world leadership in another important sector:machines for the automatic manufacturing of glass vials. Asophisticated installation produced byOcmi involves an innovativeprocess that allows vial producers to eliminate a very costly secondsterilization, which is required by law in certain countries.Technologies such as these are fundamental to the production of

high-quality glass products and are at the root of excellence invarious “Made in Italy” champions. One of these is Bisazza, a jewelof Italian entrepreneurship that produces the world’s best glassmosaics. Sales topped 133 million Euros in 2007. Established in 1956,Bisazza uses the best of Italian technology to create its products,which are sold in major world markets. Piero Bisazza, the man whoheads this family business, has preserved the history of the creationof the perfect mosaic. At the same time, he has been able to developwith the help of world renowned artists and designers, “Thatsomething extra which also comes from my classical education,” herecently stated. “That enables me to look at the contemporary froma different point of view. That’s why I love designers who know thepast—Byzantium and Pompeii—and who are, at the same time,able to reinterpret it in an innovative way.”Bisazza is a company whose success is based largely on innovationsthat come through working with a pool of world famous designersand architects. And the company also is willing to explore unusualcollaborations. For example, in 2008, it covered four Mini Cooperautomobiles with mosaics. It also has worked closely with Lombard-

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73

Bisazza, a jewel ofItalian

entrepreneurship thatproduces the world’sbest glass mosaics

based elevator manufacturer IGV on its DomusLift product, a state-of-the-art home elevator. DomusLift represents the latest trends inthe ultra-luxury market: Users can interact with a computertouchscreen connected to an MP3 player to program their favoritemusic, pairing it with lighting preferences. The elevator’s design wasdeveloped byGiugiaro Architettura, the finishings by Bisazza. Atthe IGV plant in Vignate, near Milan, 25 of 170 employees workfull-time on R&D. IGV has trumped the competition partly on thebasis of a silent motor developed in-house. The technology also doeswell abroad. Fifty-seven percent of the elevators head toward foreignmarkets such as Asia, the Middle East, the US, and Australia, butmost sales are made in Europe.But to return to glass and to Murano, the island hosts a bureau

called the Stazione Sperimentale del Vetro (“station forexperimentation on glass”), whose goal is to study and promote thedevelopment of innovative technologies for processing glass, anexample of Italian excellence that influences the artistic andindustrial use of glass across the planet.

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WORKMANSHIP OF THE PAST,

Right: Marazzi Group’s interior designsystem by David Chipperfield

Below: Ceramics leader Sacmi’s Continuaflooring production line, Sassuolo. Italianceramics are a two billion Euro industry


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TECHNIQUES OF THE PRESENT

n the years followingWWII, the ceramics industry was in German hands.Today, 60 years later, the top-notch machinery in the sector is all Italian-made.” These words by Paolo Gambuli, president of ACIMAC (theAssociation of Italian Manufacturers of Machinery and Equipment forCeramics), summarize quite well the leadership position of Italiancompanies in this sector.This leadership revolves around one of Italy’s most successful industrialdistricts: Sassuolo in the heart of Emilia Romagna. It was in this region thatcompanies such asMarazzi, Ragno, Cotto D’Este, and Graniti Fiandrestarted and flourished, leading to worldwide appreciation of Italian ceramictiles. And it was here the best technologies were invented and developed

for the production of ceramics, inventions that gave life to the most modern presses, glazing systems andkilns for firing.In 2007, the Italian ceramics sector generated almost 2 billion Euros in sales, up 20% from the previousyear. More than 71% of sales came from exports.The undisputed leader in the industry is SACMI, an Emilia Romagna cooperative that over the yearshas become a giant in the field. In the process, it has acquired three German companies that still maintainan important presence in the sector. Presently, SACMI is responsible for about 40% of the country’s salesof ceramics-producing machinery. It also has developed many of the most advanced technologies in thesector. Results have been so promising, both within Italy and on an international level, that the companyhas decided to venture into other markets such as packaging and food.SACMI’s growth occurred throughmany acquisitions but also from solid investments in technology andinnovation. Just to cite a few recent examples, there is the new robotic jewel created by GaiottoAutomation, one of the companies in the SACMI Group. Called the GA2000, it is a high-tech systemfor automated painting and was developed through a collaborative effort with Japan’s Motoman, a worldleader in robots that paint cars. In Europe the robotics market is valued at about 40 million Euros, andthroughGaiotto, SACMI aims to garner about 20% of that over the next few years.

“IC E R A M I C S& M A R B L E



SACMI also carries out advanced research in otherareas such as the technology applied to processingfoodstuffs. It has even developed an “electronicnose,” an instrument that attempts to reproduce theolfactory systems of humans and other vertebrates.The electronic nose is able to detect scents, but italso can determine levels of ripeness and whetherresidues of phytochemicals are present in fruit. Itconsists of a series of chemical sensors, eachproviding an electrical signal corresponding to itsinteraction with the volatile substances emitted bythe fruit. Software then processes the data toproduce a final report.For a few years, SACMI has been working on an

electronic nose prototype in collaboration with thebiotech unit of ENEA (Italian National Agencyfor New Technologies, Energy, and theEnvironment). It will be used experimentally at theOranfrizer plant in Scordia (province of Catania) totest its ability to ascertain the ripeness of citrus fruit.This procedure will help determine levels ofanthocyanin, the source of the pigmentation inblood oranges, and will check for traces ofphytochemicals.Returning to ceramics, SACMI, like other Italiancompanies in the sector including Siti-BT andSystem, has played an important role in thedevelopment of one of Italy’s most innovativecontributions: grès porcelain, a porcelain productthat bears a striking resemblance to natural stonesuch as marble and granite. The development of thistechnology, which permits the manufacture of tileswith a high level of slip resistance, dates back about15 years. It is another technology born in theSassuolo district, and its value derives from theproduction process. The firing of grès porcelaintakes place at temperatures around 1350° Celsius(more than 2400°F) in kilns as long as 140 meterswhere the raw materials are slowly brought to themaximum temperature, maintained there for a shortperiod, and then gradually cooled to roomtemperature. The firing process determines thequality of the final product, including levels ofresistance and longevity.The birth of the grès porcelain market, which isnow worldwide, has given life to a new industry thatuses different types of clay, firing techniques, andmachinery. It is a field in which Graniti Fiandreplays the leading role in marketing the finishedproduct, and one where the Sassuolo district haslong been the absolute and undisputed leader.

Sacmi’s “electronic nose” can detect scentsand gauges levels of ripeness and thepresence of phytochemicals in fruitsShown here, Sacmi’s reduced-energy FMPKiln and PH7500 machinery



he words marble and marble machines have long been associated with “Made in Italy”products. The ancient traditions of quarrying and sculpting natural stone are deeplyrooted in the peninsula through works of art and architecture that the entire worldrecognizes as evidence of Italy’s eminence. The marble and granite sector along withrelated processing technology is one of the country’s top industries today. It is anindustry where modern technologies have touched all production phases fromexcavation to manufacturing. During the last decade, the Italian makers of machinesand installations for manipulating marble have introduced significant technologicalchanges in the production process, changes that were required to keep up with theenormous demand for high-quality, standardized and readily available stone products.More recently, the sector has begun to use diamonds both in the quarrying and

cutting phases. The application of diamonds has greatly reduced production times while simultaneouslylaying the foundation for new uses of the materials. The industry also is benefitting from new types ofhigh-performance machinery and the addition of electronic components and computerized numericcontrols (CNC). Thanks to these innovations, marble and granite as well as other authentic natural stonesare no longer exclusively luxury materials and are now starting to be within reach of the average consumer.The Italian industry of technological stone processing equipment falls under the aegis ofConfindustria’sassociation Marmomacchine, which unites more than 330 companies and 11,000 employees. It alsopromotes, supports, and defends Italy’s undisputed leadership in this sector. Indeed, Italy accounts for 65%of the world market with 66% of its machinery being exported to countries such as India, the US, Russia,Egypt, and Spain.

TM A R B L E

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F O O T W E A R

lustered largely in threeconcentrated and integratedproduction areas, 350 makers ofmachines that produce footwearand leather goods account fornearly 500 million Euros ofbusiness yearly, 350 million Eurosof which come from exports.These numbers are evidence of thelarge economic impact of theleather goods machinery and

systems sector, which has long been synonymous with Italy’sindustrial excellence. It’s a sector that began to develop in the 1950sand today has achieved worldwide leadership through technology.More than half of the world’s machines for processing leathergoods are Italian. Italy produces more than 65% of the machinesfor the tanning industry, which is linked to the footwear andleathergoods industries as well as to the sector for automobileinteriors.There are countless instances when Italian industry has been ableto combine technology and creativity. One example is the sportsfootwear company established in 1995 by entrepreneur MarioPoletti Polegato in Montebelluna (province of Treviso). Thecompany created the celebrated “breathing sole,” which isimpermeable to water but permeable to water vapor. It hasbecome a huge international success story.Recently,Geox has invested heavily in research, registering dozensof international patents for processes used in the manufacturingof its shoes. The company, based in the Veneto region, reportedsales in 2007 of 770.2 million Euros and posted a net income of 123million Euros. Sixty percent of sales were abroad. That figure isexpected to rise to 70% or 80%, Polegato recently explained,because of innovations such as the newly released Net line ofsports footgear. Net footwear is equipped with a patentedbreathable netlike sole. “The patent at the basis of our entire lineof sports shoes calls for the superposition of a net-like layer,membrane, and sole. It has been registered in all the majorcountries of the world,” explains Polegato. He expects the new

line to be formidable competition for major sports brands such asNike and Adidas.Elsewhere, other Italian districts boast excellence in othertechnological areas. The district around Vigevano (province ofPavia), for example, specializes in the production of machineryfor shoemaking, giving rise to a pool of companies that specializein computer-assisted design and manufacturing systems(CAD/CAM). This provides footwear makers with the experienceand capabilities of design software that was first created for themanufacturing environment. Companies such asAtom, Comelzand Torielli, to mention a few, have perfected original, cutting-edge systems that are currently being used by most of the biggestnames in Italian shoemaking such as Gucci and Dolce &Gabbana, as well as many leading international players such asthe British brand Clark.Themanufacturers of Italian shoemakingmachinery always haveused technology to outdo their competition. Recently, forexample, they have been able to surpass fierce competition fromChina by producing machinery specifically designed to makewomen’s pointy-toe shoes. These devices permit shoe factories inmany countries to wrap the vamp, which covers the top part of thefoot, on the formwith extreme precision, guaranteeing top qualitywhile drastically reducing labor costs.Another element that has distinguished Italian technologicalexcellence has been its lasts, the plastic structures modeled on thefoot that are used to make shoes. An Italian company,New Last,has completely rethought the concept of lasts, which had beenneglected for decades. Romagnol started producing a new line ofCAD/CAM systems for footwear and a series of machines forproduction that are capable of producing tolerances of only one-tenth of a millimeter. “New Last has permitted producers toachieve an unimaginable level of automation, consequentlyallowing them to cut labor costs, a key factor in being able tocompete with countries like China or India where labor is muchcheaper than in Western countries,” says Sergio Stella ofASSOMAC, the association of Italian producers of machinery forthe footwear, leathergoods and tanning industries.New Last designed its new machines in close collaboration with

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ITALY, THE WORLD PLAYER

other last makers such as Romagnolo, which in turn adapted itsproduction processes to align with the newly available technology.In fact, since its inception in 1996, New Last has operated on apolicy of total openness and standardization in relation to itsmarket. In this spirit, it worked closely with a Spanish competitorto perfect a new standard format for CAD/CAM software forfootwear production called NH1. The format allows varioussoftware programs to communicate easily with one another,creating a significant synergy for all producers of footwear lasts.Among other examples of technological excellence in the field, itwould be a mistake to overlook Vibram, the maker of high-techrubber soles. Established in 1937 by Milan-born mountaineerVitale Bramani (from which the brand name derives), thecompany posted profits of more than 65 million Euros in 2007and has built a strong working relationship with the US. One ofits main suppliers, Quapaug, is in fact American as isTimberland, one of its major clients. Every Timberland shoehas a Vibram sole. Recently, the collaboration resulted ina new, eco-friendly development: under a newpartnership between the two companies, soles willbe produced with 30% recycled rubber. Socialresponsibility and eco-friendliness are twocentral themes for the Vibram team somuch so that each sole is printed with amessage about the environmentalimpact of the shoe’s production.Another piece of “Made in Italy” isMediterranea, the Italiancompany with the license toproduce leather bags, keychains and wallets forTimberlandthroughout theworld.

Geox’s Rubber Sole



T E X T I L E S

THE HISTORY, THE CHALLENGES, AND G

extiles in all their possible variations represent oneof the strongholds of “Made in Italy.” Despitemounting competition from China and other FarEast countries, textile products remain animportant asset of the Italian production system.The industry’s impact is even greater when onetakes into account the machinery used to producetextiles.Italy is currently the world’s second largest

producer of textile machines and thetechnological level of its production is considered

even by its competition to be of the highest standard. In 2007, Italyproduced textile machinery worth 2.8 billion Euros. Nearly 80% ofthat was exported to some 130 countries.The Italian industry maintains a recognized leadership position in

manufacturing machines for the production of high-qualitytraditional textiles that are used by top Italian and internationaldesigners, among others. It also excels in the high-tech market fortechnical textiles and new materials. That sector is growing rapidlyas demand increases from markets as diverse as automotive,healthcare, and sports and leisure. And as it grows, the area also isbecoming eco-friendly with increased attention being paid tosustainability in terms of reducing energy and water consumptionand recycling waste materials.The Italian company Dell’Orco Villani of Campi Bisenzio

(province of Florence), recently developed a technology for makingan exceptionally thin and highly resilient nylon yarn from discarded

office building carpeting. Cormatex, in turn, developed its Airlaidtechnology to make nonwoven fabric out of recycled automobiletires and various types of yarns. This system also is being used toproduce automobile trim and heat- and sound-absorbent panels.With 20 employees and 6 million Euros in annual sales, Cormatexdecided to diversify into new sectors. After beginning with cashmere,it turned to dealing with nonwoven fabrics where fibers are heldtogether by chemical or thermal means. “We work closely withNorth Carolina State University, but the technology under thepatent for the new machine was developed in our laboratories,”explains a company spokesperson.Still within the field of high tech, Comez in Cilavegna (province

of Pavia) is a leader in the production of traditional crochetmachines, but it is currently working with clients on thedevelopment of machines for textiles capable of releasing the correctdose of insulin to diabetics.“Within the Italian industry of textile machinery, this high

technology sector is currently worth between 15 and 20 percent oftotal sales, and it continues to grow,” explains Federico Pellegata,director of ACIMIT, the association of Italian companies thatproduce textile machinery. “And Italian companies also maintaintheir leadership in the creation of machines for the production andennoblement of yarns and textiles, ranging from the most‘traditional’ to the most highly prized, those that are produced andutilized by historic “Made in Italy” brands like Loro Piana andErmenegildo Zegna.”The collaboration between innovators in the fields of technology

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and textiles is a key element of Italy’s excellence in the textile sector.This is the case atNext Technology Tecnotessile Società Nazionaledi Ricerca r.l., partially funded by the Ministry of Education andResearch, which is making its way into sectors previously reservedexclusively for materials of chemical origin. Some examples includetraditional fabrics that with the help of nanotechnology can purifyair of carbon dioxide or prevent work overalls from getting dirty.And then there is a processing technique that creates a waterproofand breathable fabric similar to Gore-Tex except that it is made fromall-natural materials. These creative ideas represent the sole means ofsurvival for many small companies that can no longer compete inlarge-scale textile markets and must focus on innovation, low energyconsumption and eco-friendliness. All this is taking place at a timewhen sales are merely lukewarm after years of contraction that wassparked by an influx of Chinese producers which reshaped theworld textile industry completely.Also based in Prato with Next Technology Tecnotessile is

Unitech, a company with nearly 20 million Euros in annual salesthat specializes in taking fabrics to new levels. Thanks to itscollaboration withNext Technology Tecnotessile, it has developeda plasma-technology machine for the production of membranefabrics. “We make a great effort to remain competitive on a marketthat changes on a daily basis,” the founder explained recently,recalling how he decided to merge with a competitor in order tokeep his business afloat. “Customer service, technical support,software: just having a good product is no longer enough.Withoutthese capabilities, it is no longer possible to win over a client.”

A model wears a creation from theSalvatore Ferragamo Fall/Winter2009/2010 fashion collection, presented inMilan, Italy, March 1, 2009(AP Photo/Antonio Calanni)

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It’s no secret that over the past few years the European textileindustry has struggled with fierce competition from the Far East. Inorder to compete, some companies have used a winningcombination of high tech and a shorter supply chain. Oneinteresting project in the sector is the Blulino brand, an alliance ofvarious key European linen producers. The brand guarantees thetraceability of the origins of the product, which carry the “Made inEurope” assurance of quality. The idea was born in Lombardy at theinitiative of Linificio &CanapificioNazionale S.p.A. in Fara Gerad’Adda (province of Bergamo). Linificio is part of the MarzottoGroup, the Italian leader in industrial production of linen fiber andhemp spinning. With an annual production capacity of 1,500 tons,the company supplies 35% of the national market.“The idea arises from the need to resist what can be called atrivialization of the product,” Linificio company sales managerCesare Losavio stated recently. “It’s this chasing after the lowest pricesthat’s pushing the market quality down.” The Blulino brand is themeeting point between French farmers of the Normandy regionwhere Europe’s flax farms are concentrated; Linificio Nazionale,which produces the yarns; cotton millAlbini, a leader in producingshirting fabrics; and a number of weavers of apparel and domesticproducts. Through Blulino, companies can offer their clients a widearray of choice fabrics and yarns overseen through all phases ofproduction: from the selection of raw materials, consisting only ofthe top pick from each harvest, to the processing of yarns using themost advanced techniques, all the way to the production of the top-quality final products.In 2007, Linificio posted sales of 53.5 million Euros, of which 10%

derived from the Blulino brand, while Marzotto Group’s corebusiness, traditional raw-white yarns, was valued at nearly 52 millionEuros. Linificio sales were expected to increase to 56 million in2008, with exports accounting for about 55% of that.A coconut yarn that can absorb and neutralize environmental

odors: It’s Cocona, a fiber derived from the transformation ofagricultural and food leftovers that was developed by Sinterama, acompany established in 1968 in Sandigliano (region of Piedmont)where the textile culture has deep roots. The Sinterama Group iscurrently the European leader in the production of colored polyesterthreads and yarns. Each year the company produces 30,000 tons ofyarn in 400 different types for a wide range of uses: automotive,home furnishings, and clothing. Total sales in 2008 reached 120million Euros. “In recent years, commodity products in our sector

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have come under the control of the Asian companies.We’ve focusedour attention on colored yarns with a high-service content,” saysSinterama President Paolo Piana. He adds, “We are presentlyworking on three different fronts: on yarns, where we are constantlyresearching new and more sophisticated characteristics; on fabrics—the product of our clients—where we are looking to improve andexpand the level of our performance; and finally, on our installationsand the automation of our support systems, where we are workingto satisfy demands for increasing quality standards and flexibility.”Six percent of sales are invested into research and development,

but the innovative potential of the Biella-based company is basedon a local network of textile machinery producers such as Obem.Obem, also based in Biella, specializes in the production ofmachines for dyeing fibers in a variety of forms from loose fibers tohanks.Obem has even developed its own internal software divisionfor CAD/CAM management and support of its technologies.Headquartered in Bollate (province of Milan), Loris Bellini S.p.A.produces machinery for dyeing yarn packages, hanks, and pieces, aswell as hosiery. It recently launched its new READY system (RapidEconomical Adapted Dyeing of Yarn) for dyeing carpet yarn on bobbins,which was developed together with Germany’s Dystar and othercompanies in the sector. Bellini exports 80% of its devices.Sinterama has a substantial global presence: 70 people, both

salespeople and agents, follow more than 1,600 clients in 40countries. Some 750 employees work in the company’s eight plantsin Italy, France, the UK, Brazil, Turkey and China. Fifty percent ofthose are in Italy and another 25% are based in other Europeancountries. A high degree of automation ensures high quality andflexibility in serving customers. “Sinterama can boast an importantand far-reaching role in the Italian textile industry by virtue of itsclientele. This partnership, focused on fulfilling the demands of amarket that is among the most selective in the world and among themost advanced as far as technology and creativity are concerned,places us in a situation of necessary and continuous improvement,”says Piana. The company’s innovations also result from its continuingrelationships with Italian universities.The FlexiFunBar research project of the European Union’s Sixth

Framework Programme generated a partnership between Sinteramaand the Polytechnic University of Turin. Within the context of theproject Industry 2015: New Technologies for “Made in Italy”, Sinterama iscollaborating with the Polytechnic Universities of Milan and Turinand the University of Perugia.

A model wears a creation as part of theGiorgio Armani Fall/Winter 2009/2010fashion collection, presented in Milan, Italy,Feb. 27, 2009 (AP Photo/Luca Bruno)

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F O O D

SECRETS FROM THE LAND OF G

he only way to learn how to build excellentmachinery for the production of goods is throughproducing the goods themselves. This rule holdstrue for all production sectors, but it is especiallytrue in the food industry. Behind this lies thereason for the excellence of Italian machinery forthe production and preparation of foods. Noother country comes close to offering such a widevariety of food products, and it is indeed in Italy’srenowned food-producing districts that some ofthe most advanced technologies exist for

production, processing, preserving, and packaging food products.A prime example is FoodValley, located in Parma, home to some

of Italy’s most famous foods, which include Parma ham (prosciutto diParma) and Parmigiano-Reggiano, the original parmesan cheese.FoodValley’s technological excellence is focused on machinery for

processing vegetables such as tomato sauce, a key ingredient in Italiancuisine. “Parma’s food processing machinery industry started withthe sugar industry at the beginning of the 20th century and thenevolved into the tomato processing sector,” explains RobertoMasini,professor at the State University of Parma. “Today, the district is theworld leader in this sector and among the top in others as well, likeaseptic food packaging.”Over the years, Parma’s Food Valley has become a center of

worldwide attention. Italian company Rossi & Catelli S.p.A. playsa key role in the district, but there also are manymultinationals fromthe Swedish Tetrapak to the American Food Machinery Corp.,

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which have moved their R&D centers to Parma because of its know-how. Cibustec, Parma’s food machinery fair, is an event not to bemissed by anyone in the industry.Rossi & Catelli posts annual sales of about 60 million Euros and

employs more than 140. It recently delivered two systems forconcentrating tomatoes to China’s Xinjiang Tunhe Chang Tong TomatoProducts Co. Ltd. and Xinjiang Tunhe Wusu Tomato Products Co. Ltd., whichare capable of processing, respectively, 4,300 and 2,200 tons of freshtomatoes daily.Rossi &Catellimakes significant investments in hightechnology, and a few years ago it devised an innovative system forprocessing diced tomatoes and fruits called Macropak Magnum.The food machinery industry is extremely complex so much so

that even related trade associations have a hard time keeping up withits variations. According toASSOFOODTEC, the association thatbrings together the largest number of businesses in the sector, Italiancompanies generated 2007 sales of more than 3.5 billion Euros, 2.2billion Euros of which derived from exports. These figures includemachines that are very different in nature--from refrigerating unitsto ovens, from espresso machines to meat-processing equipment. Ontop of that, there are machines that process fruit, milk, and ice cream.For Italy, this ensemble of machinery represents a fundamentaleconomic resource. For the rest of the world, it represents a sourceof technological excellence difficult to find elsewhere.In terms of sales proceeds, Italy is second only to Germany. That is

a big change from a few decades ago when Italy was a follower andnot a leader. Until World War II, Italian production of food-processing machinery was small but the upturn was swift and

effective. In the 1970s, the University of Milan founded DISTAM,the first department for food sciences in an Italian university.In the area of pasta-producing machinery, two Italian companies

dominate the Italian market because of their investment intechnology: Fava of Cento (province of Ferrara) and Pavan in Padua.Fava, which has been operating in the sector since 1937, has patentedand built machines for the production of dry pasta, earning the trustof the largest producers in Italy and worldwide. A family-runcompany for three generations, Fava is headed by Enrico Fava andhis son, Luigi.Since its inception Fava has been dedicated to research, turning a

specialization in dry pasta into a strong point. In 2008, the companyposted sales of 72 million Euros for its high-tech lines of dry pastamachines. Sales were strong in major pasta-producing countries suchas Italy, Spain, France, and the United States. Other importantmarkets include the principal countries of North Africa.Exports account for more than 80% of sales with emerging markets

in the Middle East and elsewhere fueling growth.Pavan has been investing for decades in R&D and technology,

optimizing its processes and systems for drying at very hightemperatures. It has long supplied the machinery for Barilla andother multinational producers. In time, the logic of the productionchain won out, and now producers of machinery and foodstuffs areworking together in harmony.The Pavan Group of Padua exports more than 95% of its

production with a diversified portfolio that ranges from dried andfresh pastas to precooked and frozen meals. It also processes cereals




and is involved in creating packaging.Its reference market is composed of some 1,000

producers, big multinational businesses such asKraft, Nestlé, PepsiCo, Barilla, Kellogg's, Conagra,Molinos, Rio de la Plata, Procter & Gamble, andRana. Pavan’s machinery is produced in 120countries, and the company has branches in Poland,Russia, the US, Mexico, and Argentina.In 2008, the Pavan Group, headed by CEO

Andrea Cavagnis, reported sales of 90 million Eurosand a consolidated profit of 6.7 million Euros, a 46%increase. During the previous five years, sales haveexpanded by 66%.Continued investment in innovative technology is

one factor that keeps the group’s companies socompetitive on the world market.In a slightly different direction, Storci, a company

based in Parma that is part of the Fava Group, hasdeveloped a specialty in the area of fresh pasta andbakery goods. Storci recently has developed newmachinery allowing production of bread and pizzadough in continuous cycles, which preserves itsnatural characteristics. The technical and high-techimprovements also lower energy consumption.Together, Fava and Storci use cutting-edgetechnology to build some of the most importantmachinery for production of couscous, an importantstaple in North Africa and the Middle East.Italy also maintains a strong leadership position in

the sector of packaging machinery where producersare united under the aegis of UCIMA, the ItalianManufacturers of Automatic Packing and PackagingMachinery Association. Exports approached 90% ofthe total sales in 2008, which totaled more than 3.6billion Euros. Combined, Italian companies hold26% of the world market, compared with 33% byGerman companies.“Italy’s success is based on two factors,” explains

Guido Corbella, CEO of Italy’s leading trade show inthe sector, Ipack-Ima. “Firstly, because we orientourselves toward small- and medium-sizedbusinesses, we are great at working closely withclients, developing machinery that fits their specificneeds. Secondly, we’ve been able to create an

integrated district in Emilia Romagna where thepackaging machinery producers dialogue closelywith the packaging producers. The key to the qualityof our R&D lies in just this dialogue, and hasgenerated a large number of successes.” The blisterpack – that combination of plastic and paper usedfor packaging medicines – was invented by IMA, acompany in Bologna.Italian producers of machinery for farming,

gardening, and earth moving are represented by theassociation UNACOMA. Once again, they comein second place on the world market, this timebehind the US. Annual sales in 2008 amounted to 13billion Euros, 70% of which derived from exports todeveloped countries with their own very qualifiedplayers. Sixty percent of exports went to Europewhile 10 percent were directed to the United States.Italian companies lead the world in terms of thevariety of products, a consequence of their havingremained connected closely to their respectiveterritories. Around the rice paddies of Piedmont, forexample, companies that prospered were the onesthat developed machinery for harvesting andprocessing rice. That trend holds true even today.Recently the University of Palermo and severalcompanies promoted a research program for newmachinery capable of adapting to crops typical ofthe small islands around Sicily such as straw winefrom Pantelleria and capers.It is a small step from packaging machines to

machinery for the graphic arts industry, which isrepresented by the trade association ACIMGA.And in fact, Italy is a world leader in this sector aswell with exports totaling 78% of total sales, whichapproached 1.7 billion Euros in 2008. It is a marketthat continues to grow albeit slowly due to thefinancial crisis.Italy also commands a leadership position in

machinery for rotogravure and flexographicprinting, as well as converting machines for paper,cardboard and other materials. The majority ofproduction is absorbed by the packaging marketwhile the smaller graphics sector accounts for nearly35%.

Pavan Tecnologie conducts research into the agro-industrial sector and offers training in new processing

techniques at its School of Food Technologies

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In 1937, an original ideaof founder, Augusto

Fava, created the firstcontinuous short goodsdryer: the "Trabatto"(shaker pre-dryer),

marking the beginningof Fava's dryer

manufacturing activity.High temperaturedrying technologyrepresents the most

important technologicalinnovation in pastaproduction to date



espite the developmentof new constructionmaterials, woodremains a fundamentalresource for residentialand commercialbuilders. In fact, thelast decade has been aperiod where the usesof wood haveexpanded far beyond

the traditional. Wood is a resource that hasalways been a strong suit for Italian companies,which have developed new technologies forproducing door and window frames, furniture,roofing, stairways, and flooring—any sort ofproduct that uses wood as an integralcomponent. Italian expertise extends all the wayto veneers of prized woods no more than a fewtenths of a millimeter thick used for coveringpanels made from salvaged or recycled woods.Essentially, wood processing takes place in two

phases. During the first, panels are made fromsolid wood or chipboard; during the second,these intermediate materials are furtherprocessed into furniture, window and doorframes, flooring, etc. Italian companies are nolonger very active in the first phase but they

dominate in machinery for the second. TwoItalian groups, SCM of Rimini and Biesse ofPesaro (region of the Marche), dominate thissector with combined annual sales of 1 billionEuros, about 40% of the entire country’sproduction.The sector of woodworking machine makers,

like other Italian industries, is composed of afew big businesses andmany smaller companies.They export more than 80% of their production,mostly to Europe but also to Russia, Canada,and the US. Italian machinery, second only tothe German industry in terms of sales, is usedby major furniture builders around the worldincluding Sweden’s Ikea. The sector comprisessome 300 companies with 12,000 employees and2008 sales amounting to 1.85 billion Euros,according to ACIMALL, the Confindustriaassociation representing the category.As with some other sectors, the history of

Italian woodworking machinery is fairly recent.The sector started developing in the 1950s, butgrew quickly through the introduction oftechnology related both to the product and toits processing. For example, the first CNCdrilling-and-milling system was developed inItaly, revolutionizing the sector in the 1970s.Production sectors such as chair and table

NEW GENERATION,

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manufacturing, which involves sectioning,drilling, and surface finishing, are examples ofareas where Italy excels. If Italy’s wood furnituresector is among the first in the world today, partof the credit goes to the companies thatdeveloped and marketed new technology andwere able to grow by providing the rightsolutions to meet customer demand.A more recent example comes fromDelmac,

a company recently incorporated into the SCMgiant, which has developed and perfected arevolutionary system for furniture productioncalled “Strip Processing”. Using this technology,the furniture elements are manufactured instrips in a high production setting and then cuton demand into smaller parts. The base stripscan easily be stored in a warehouse – savingspace andmanagement costs. Custom furnituresizes can be marketed and assembled ondemand yet taking advantage of economicprocessing methods. Delmac has successfullyinstalled this technology in both foreigncompanies initially and today, it is nowcommonly used by many Italian furniturebrands. Another recent innovation by a leadingItalian importer in the USA - DelmacMachinery Group and Busellato S.p.A. is aprocess called “Linear Flow” and is based on

using a CNC router for nesting all furnitureparts. This technology recently won the SequoiaAward forMachinery Productivity at the recentAWFS Tradeshow in Las Vegas.SCM leadership is driving a district that is cited

as an example of excellence even abroad. Theindustrial district for woodworking machineryin the province of Rimini has recently given riseto a new, extremely specialized college degreethat concentrates heavily on high technology.In the capital of the Emilia Romagna region,

an agreement between the University ofBologna and industrial trade associationspermits the granting of mechanical engineeringdegrees with specialization in this particularsector. The three-year program is offered by theengineering department and is co-financed bythe industrial trade associations with the goal ofproviding highly qualified personnel needed inthe sector.In recent years, Italy has developed expertise

in numerous other areas complementary to thewoodworking sector. Among them arecompanies involved in painting, coating, andlacquering, which are part of the cooperativeCEFLA (also in Emilia Romagna), which hastaken on a leading role, dominating foreignmarkets as well.

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ANCIENT ORIGINS


With sales totaling 169 million Euros in2007, 20 million meters of fabric andover 1,400 employees, Cotonificio Al-bini is the undisputed leader of Europe’scotton and linen shirt market. The com-pany was established in 1876 in Bergamoand has been able to reach theseheights through keeping constant watchon innovation for its products, productionand distribution processes.

What matters in a shirt

“In a market like ours, process innovationis fundamental,” explains company CEOSilvio Albini. “We take advantage of themost cutting edge computer technologiesto improve our factories.We work closelywith machinery manufacturers, like thePromatec Group of Bergamo, to createequipment that is always new, always onthe cutting edge. It is only through thistype of effort that we are able to produce14,000 different varieties of cotton andother fabrics in a given year.”


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C O T O N I F I C I OA L B I N I

THESTORIES


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The weaving loom is one of thecentral elements of the textilesector’s production process.Collaboration between those whoproduce the yarns and those whoproduce the looms is one of thecornerstones of innovation. Theprocess is being improvedconstantly. There is oftencollaboration in designing thedetails of processing equipment,whether it is focusing on theimprovement of an individualprocess or even working on existingparts of the machinery to make theentire production process moreefficient and dynamic.Constant product innovation is

Cotonificio Albini’s other strongpoint. A few years ago, for example,the company was the first in theworld to start using compact yarns,taking advantage of agroundbreaking spinningtechnology developed in a Swissuniversity laboratory; all of itsequipment was upgraded shortlyafterwards. Through theirpioneering spirit, they were able toachieve a refinement of both designand spinning that was previouslyimpossible, while substantiallyincreasing the fabrics’ resistance.Not long after, a large number ofcompetitors chose to follow suit butthe competitive advantageCotonificio Albini gained fromtheir early decision can still be seenin today’s financial results.

Today’s Weaving Loom.Cutting-edge spinning technology creates

strong, compact yarns

Right: Example of woven Albini fabric

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Cotonificio Albini has alwaysperformed scrupulous research ontheir raw materials, even to thepoint of personally picking cropsthat will best suit their productionneeds, as was the case in the Blulinoproject. At the center of the projectwas an alliance between variousfigures in the European linenindustry. The project began inLombardy, Italy, on the initiative ofa number of companies, including

to collaboration with the world ofuniversities and research. A newdegree in textile engineering fromthe University of Bergamo is beingpromoted by Cotonificio Albiniand other fabric businesses in thearea. This degree program iscurrently producing new specialistswho are joining local productionnetwork upon graduation.“This enables us to significantly

improve the scientific training of

our technicians,” Silvio Albini says.The company has also begunworking closely with thePolytechnic University of Milan todevelop forecasting models that willallow the company to respondbetter to market demands.

Through Blulino, companies canoffer their clients a wide array ofchoice fabrics and yarns that areoverseen through all phases ofproduction: from the selection ofthe best raw materials, to theprocessing of yarns using the mostadvanced techniques, all the way tothe production of the top qualityfinal products.The attention paid to the selectionof rawmaterials lends itself naturally

Cotonificio Albini and Linificio& Canapificio Nazionale, in FaraGera d’Adda. The Blulino is now amark of “Made in Europe”excellence in quality and traceability,bringing together flax growersfrom Normandy, Northern France,where most of Europe’s flax farmsare found; the LinificioNazionale,yarns producers; the Albini cottonmill; and a number of weavers forclothing and domestic products.

The research

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cqua di Parma’s success is inextricably linked tothe preservation of tradition.” says Paola Paganini,Group ProgramManager forAcqua di Parma. “Butin today’s complex global market, this objectivecan only be obtained by using avant-garde methodsand technology.” This successful Italian companyhas been recognized for its leadership in theluxury sector for decades. Acquired in 2001 by theLVMH Group, the company has always kept therecipe for its cologne a secret, handing it downfrom generation to generation. The fragrance is

chosen by VIPs around the world including numerous movie stars, includingHarrison Ford, Kevin Costner, Kate Moss and Cameron Diaz. Today, however,the systems the company uses to produce that same cologne and its otherproducts, which are sold by 1,700 select retailers worldwide, have substantiallychanged. The selection of essences, for example, is carried out in partnershipwith some of the greatest specialist multinationals in the sector.

“ATRADITION AND FLIGHTS FORWARD

NATURE

The essences used byAcqua di Parma are, andwill always be, rigorously natural,but today’s technology allows the use of more sophisticated raw materials.“Todaywe canmake use of a bergamot that is much purer andmore highly prizedthan we could in the past,” explains Paola Paganini, “At the same time, we canstill guarantee the same level of cleanness and hygiene demanded by ourclients.”Established in 1916, theAcqua di Parma brand has expanded over the years withthe Home Fragrances Collection of perfumed candles for the home, the HomeCollection of linen and terrycloth bath sets, Travel Collection leatheraccessories, Collezione Barbiere products and accessories for shaving, and theBluMediterraneo and BluMediterraneo Italian Resort lines of fragrances andcosmetics inspired by the most exclusive natural scenery of theMediterranean.Acqua di Parma has always remained faithful to its roots and to the alchemyof an ancient wisdom. Fragrances are still distilled by hand, just as thepackaging is also designed by hand. They are produced by artisans who use thesame methods as those used in the past.

Tradition and modernitygo side by side for Acquadi Parma, with a line ofproducts that both respectthe history of the brand

and threads to newterritories

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n the luxuryfabrics sector, ifthe productsrequire hightechnology, thenthe processesused to producethem do evenmore so,” statesPier Luigi LoroPiana, CEO forhis eponymous

brand. The company has beensynonymous with utmost quality forover twenty years and sales exceeded420 million Euros in 2008. It hasprovided wool and cashmere textilesto the most sophisticated anddemanding clients for six generations.It is the world’s largest singlepurchaser of finest wools and thelargest processor of cashmere.One of the more recent andoutstanding innovations to come outof Loro Piana’s incessant research isStorm System Treatment. This is a newprocessing procedure that hasallowed wool, cotton, and cashmereto be reintroduced to the sector ofsporting and extreme apparel, whichhad previously been dominated bysynthetic fabrics.

“ITHE VALUE OF THE FABRIC

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Baby cashmere is not easy tofind. It is obtained from theunderfleece of Hyrcus goatkids. The fiber is gathered bymeans of a delicate andcompletely harmless combingthat is only done once in agoat’s life between three andtwelve months. A set ofpictures illustrates the process

An exclusive patent dating back to the early 1990s,Storm System is a treatment technique that protectsthe body from the elements to maintain a state ofabsolute well-being, without altering the feel orcharacteristics of the highly prized fibers. Thesystem consists of two forms of protection: the Rain

System waterproofing treatment and a series ofabsorbent membranes, which render the fabricwater and wind resistant, yet breathable.When it isapplied to the fabric’s surface, the Rain SystemTreatment forms an invisible coating around eachfiber. This coating makes water slide off the surfaceof the fabric, while also protecting it from dust, dirt,and liquid stains. Coats and jackets made out oftraditional fabrics can be made as resistant to wind

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Loro Piana pays close attention to environmentalissues. In the 1980s it installed the first cogenerationunit in the historic Quarona plant. A new unit,currently under construction, will reduce carbondioxide emissions by 40% in a few years’ time. Inthe 1990s, the company worked with the Universityof Turin to develop an innovative system based onactive carbon absorption, which allows the returnof waste-water directly into a river without any riskof pollution.

and water as technological synthetics. In order torealize this system, Loro Piana developed originalproduction installations and built completely newmachinery.Loro Piana has always been set apart by its

innovation in production processes. It was the firstin the sector able to handle spinning and spoolingusing a single machine. Loro Pianawas ahead of itsdomestic and foreign competition when itintroduced automated unloading and advancedautomation of packaging in its spinning line. Overtwenty years ago, the company introduced roboticsin its plants, using technology that had, up to thatpoint, only been used in the automotive sector. Suchinnovations have contributed considerably to theimprovement of processing procedures, making itmore competitive and allowing it to produce betterproducts.Loro Piana uses raw materials suppliers from

across the world, selecting from among the finest onthe planet and making quality assurance checks atevery step. A few years ago, the company registeredthe Zelander brand, signing an agreement with agroup of New Zealand producers. They nowproduce their wool exclusively for the Loro Pianaand, as part of this contract, they select specificanimals to produce wool with an optimal length-to-fineness ratio.

Environment



Vibram’s story begins about 70 years agowhen its founder, Vitale Bramani, had anidea. He was an enthusiastic mountainclimber who once witnessed the deathof several friends in an accident. Hedecided to develop a rubber sole thatwould prevent climbers from slipping onice. The idea quickly turned into apatent (something rare, for those days)and the patent turned into a company.

THE MAN AND HIS DISCOVERY

Mold Of Vibram’s rubber-based reinforced insole.The company’s philosophy rests upon its founder’s

commitment to eco-friendlinessand social responsibility

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Vibram today is a world leader in theproduction of soles for outdoor footwear,producing 35 million pairs every year. Salestotal 70 million Euros, which rise to 100million with the American licensee,Quabaug. Today,Vibram has no rivals on themarket. “There are many suppliers of rubbersoles around the world,” explains AntonelloGhignone, who is in charge of the company’sR&D division. “But Vibram is the onlycompany in the sector that has, as one of itsassets, a brand name that is recognizedworldwide. We have had to turn downnumerous requests by shoemakers whowould like to place their name next to ourson the sole.”The company supplies soles to numerousglobal brands of outdoor wear, includingTimberland, whose relationship withVibram is continually evolving. A newpartnership between the two anticipates

production of soles using 30% recycledrubber. Social responsibility and eco-friendliness are two central themes for theVibram team: they even print theenvironmental impact of the production ofthe shoes on each sole.

The company, based in Albizzate (inVarese, Italy) manufactures its product usingtechnology it had developed itself, along withthe support of partners in several countries.Forty percent of the soles come fromChinese plants, with the remainder comingfrom Europe and the United States. Theyare produced using a sulfur vulcanization ofrubber, to which reinforcing agents and a fewadditives, are added. Italian suppliersproduce the molds to Vibram’s originalspecifications and designs. By contrast, the

The technologies

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machinery used by the company is quitestandard. The company also collaboratesactively with the Polytechnic University ofMilan and with the State University of Pavia.Vibram also works with the Italian NationalResearch Center’s Institute for Technologyand Automation (ITIA) to integrateshoemaking production processesthroughout Europe, so as to make themmore standardized and easier to customize.When asked about the company’s biggestcompetitors, Antonello Ghignone statedwryly, “Vibram’s greatest rivals are our ownclients, in the sense that any one of them hasthe possibility, at any time, to investigatesuppliers who provide cheaper products of alower quality. Because of this, we arecondemned to continue offering increasinglyefficient and excellent soles,” concludedGhignone, whose strategy seems to findsupport in the company’s figures.

Vibram’s internationally-recognized brand is linked to its pro-prietary rubber sole, which is designed with sulfar and otheradditives including 30% recycled materialsThe company's premium collection, known as FiveFingers, is aline of barefoot performance footwear that utilizes the technol-ogy of the Vibram sole and was originally conceived for outdoorsports. Now the products are worn by climbers, fitness enthusi-asts, runners as well as water sports lovers and are known fortheir warmth and their grip, performance and control


When Salvatore Ferragamo returned to Italy from theUnited States in 1927, he brought with him his extraordi-nary creativity and an idea for the most advanced pro-duction strategies. This idea influenced not only thecompany he was about to create, but also the many crafts-men who worked with him. Since then, the company hasalways struck exactly the right balance between creativityand innovation, registering more than 400 patents: a recordin the world’s fashion market.In 2008, Ferragamo posted sales of 691 million Euros, withoperating profits of 64 million Euros, and net profits of 39million Euros. But the scale of this company can only re-ally be understood by visiting its historical archive in Flo-rence.“We have 13,000 models of shoes here, which document thehistory of footwear and fashion,” explains Stefania Ricci,archive director. “The innovations introduced by Ferrag-amo are countless. They go from wedges in 1937 to specialheels with a shell-shaped sole inspired by Native Americanmoccasins. They include the celebrated gold shoes of the1950s and the latest anti-shock heels. Innovations intro-duced duringwartime, such as nylon and cellophane shoes,are part of the archive. They received the prestigiousNeiman Marcus award, the Oscar of the fashion world.”

Salvatore Ferragamo:master shoe builder. Hisvision led to the company’sregistering 400 designpatents, a fashion industryrecord, and its winningthe coveted NeimanMarcus award

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Ferragamo’s attitude toward innovation also influences the othersectors in which the company presently operates. In the leathergoods division, for example, they launched a line of highly eco-friendly and sustainable handbags in spring of 2009. The new EcoFerragamo collection of handbags is produced using systems thatdon’t have any environmental impact, as certified by the SG-MarkInstitute. The entire product line is produced with an innovativeecological tanning process that does not require the use of metals.Dyeing takes place using tannins of plant origin exclusively obtainedby processing tree bark. The majority of the raw materials used inthe production of these bags originate in Italy, as Italian tanners areamongst the best in the world.The Eco handbags are only the latest in a series of innovations

where research on materials has played a fundamental role. Sincethe 1990s, Ferragamo has been creating a handbag with a handlethat is made using a different material each year: wood, Plexiglas,carbon. Production of the handles is always studied down to thesmallest detail, and sometimes requires the commissioning of ad-hoc machinery from external suppliers.

Ferragmo’s designs have beensynonymous with footwearinnovation for decades. Inwartime, the companypioneered the use of cellophanein its models instead of shoeleather.Far Right: Ferragamo’s designfor WedgeHell, 1937Near Right: Stilettos, 1958

Shoes remain the company's core businessand its creative engine. Their high qual-ity is based on the maker's attention tomodel construction and to its dedication tothe manual tradition that continues to bea feature of the production cycle



Salvatore Ferragamo has long soughta good relationship with theacademic world. As early as 1998,the company had instituted aninternational competition dedicatedto students in universities and artschools, asking them to designcreative and ergonomic shoes, payingspecial attention to the materials.Ferragamo currently has continuingrelationships withmany universitiesand academies, amongwhich are thePolimoda in Florence and thePolytechnic University of Milan.


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“We have created anti-smog fabrics andshirts that release minerals and vitamins topeople playing sports, as well as clothing thatcan repel insects or dirt,” says Solitario Nesti,the company’s director general. “Weachieved this by altering the chemicalstructure of the fabrics in such a way thatthey are able to absorb the active ingredientand then release it gradually.” NextTechnology Tecnotessile also promotesinnovation within its collaboratingcompanies, such as Unitech, a companyspecializing in enhancing fabrics. It hasdeveloped plasma-technology machinery toproduce membrane fabrics capable of

substituting acoustic speakers.Among Next Technology Tecnotessile’s

successful synergies is Annapurna, a smallbusiness also located in Prato, near Florence,with yearly sales of 10 million Euros. One ofits specialties is the spinning of two-plythreads—two threads are twisted together toprovide the weight and thinness of a single-ply thread but with added strength andelasticity. At the last edition of the PittiImmagine fashion trade show, Annapurnapresented its mosquito repelling’ ensemble,the Golf-Kit: a polo shirt with a pocket anda vest fitted with a ball pouch on the back,made of cashmere and cotton.



THESTORIES

NEXT TECHNOLOGYSocietà Nazionale di Ricerca r.l. TECNOTESS ILE

a solid state when the material is beinghandled, the textiles produce no healththreat to those coming into contact withthem.“Taking advantage of technology patented

by the Colorobbia Group, we were able toapply the nanoparticles after dispersing themin an aqueous solution,” Nesti explains. Bydipping the fabric into this solution, thenanomolecules (covered by a polymer film)attach themselves to the surface of the fabric.At that point, the article of clothing acquiresproperties to shield UV rays or to impedeproliferation of bacteria, all without anyfurther precautions by the wearer.

Next Technology Tecnotessile is alsoworking toward the development andmarketing of a T-shirt made of a textileembedded with titanium dioxidenanoparticles. This would mean the T-shirtwould be capable of protecting the personwearing it from UV rays, an idea developedfrom various lines of research onnanotechnologies carried out with the helpof funds from the European Union and theRegion of Tuscany.The results achieved to date are very

promising. At Prato, they found the means toanchor nanoparticles permanently to thefabric. As the nanoparticles will never be in

Left: Creating a fabric usingnew waterproofing technology.Other projects are in develop-ment to produce dirt-resistantand mosquito-proof fabrics

The company sponsors researchin the textile sector to createnew fabrics and machinerythat alters and anhancesthreads for clothing, featuringproperties including UV pro-tection or antismog

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THESTORIES


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“It is not difficult to identify some thirty substances that will negativelyinfluence our perception of a cup of espresso,” says Furio Suggi Liverani,director of research and innovation at Illycaffè. “But understandingwhat stimulates positive sensations is very complex.” Illycaffè has beencommitted to the appreciation of coffee since 1933. In 2008 thecompany’s sales were 280 million Euros, with net profits of 8 million.In 75 years, Illycaffè has registered 201 patents, themajority being for

the production process technology that was developed in-house. Theselecting machines are further evolutions of systems over the past 20years. Each bean is analyzed individually by a computer using laserbeam refraction, allowing rejection of any that do not conform toqualitative standards. The successive phase of toasting, as well, utilizesmachinery produced by Italian companies. Exports by Italiancompanies active in this sector of the industry have reached an overallvalue of 200 million Euros.The technologies for pressurization patented by Illy in 1936 enable

the company to sell coffee to clients involving transportation over longdistances. In recent years, scientists have discovered that procedures ofpressurization preserve freshness and increase quality, owing to thecounterbalancing effect generated by the inert gases. There are fourmain packaging formats for the product: the 250-gram package forhome use; the 3-kilogram canister; and pods and capsules forcommercial uses. The company’s quality control process follows theKaizen philosophy (from Japanese kai, ”continuous”, and zen,

The company's philosophy expands beyond theimportance of selecting the highest quality coffeebeans and its prized expertise in their roastingand grinding. Coffee lovers are educated to choosethe most appropriate coffee-machine for theirneeds (see above), on the basis that 'the better thecoffeemaker, the better the coffee you'll make'.


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”improvement, wisdom”). There are 783 Illy employees around theworld, with 28 managers, 72 marketing specialists, and 14 peopleinvolved in R&D at the headquarters in Italy.Recognized officially by the Province of Trieste in 2006, the coffee

district brings together a group of companies specializing in logistics,processing, decaffeination, roasting, and chemical analysis. Thisnetwork of Italian companies also relies on collaboration by strategicpartners. For example, the University of Trieste’s Department of LifeSciences houses the world’s largest collection of coffee plants. The city’sport on the Adriatic is one of the busiest on theMediterranean and isthe gateway to eastern Europe. Over half of Illy’s sales are exports:every day their coffee is served in more than 140 countries. The“Università del caffè” (Coffee Universities) established in 15 differentcountries contribute to the global diffusion of a culture, to thespreading of know-how, with students numbering almost 10,000.“The goal of our strategy has been broadened, from the semi-finished

product to the cup of espresso. We need to consider the service, theenvironment, the perception of quality. Ours is a holistic approach,”says Andrea Illy, president of the company. These aspects have becomethe philosophical pillars of Espressamente Illy, the chain of Italian-stylecafes now present in 30 countries.

Illy’s technology uses laser beam refraction to individually select coffeebeans that conform to its processing standards. At the next phase, itspressurization technique permits the transportation of coffees to clientsover long distances without compromising quality. In Trieste, anetwork of companies collaborate on the logistics, processing andmarketing of espresso

Illy’s pre-measured espresso pods or capsules are designed for speed –each one can produce a fresh cup within 30 seconds after insertion intoa compatible machine such as these (left). Extraction occurs insidethe capsule so that the coffee never comes into contact with themachine

Illy commissions artists to create its series of collector cups (below).Works by Julian Schnabel, Jeff Koons, Joep van Lieshout and SimonPearce are among the range


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onnafugata’s adventure into the world ofwine began in the historic cellars of theRallo family in Marsala, built in 1851, andin a vineyard in Contessa Entellina(province of Palermo) in the heart ofwestern Sicily. The same family has led thebusiness along the road of quality andattention to detail for over 150 years, alwayskeeping their belief in the potential of theirnative land for producing good qualitywines. The vineyard is now run by

Giacomo Rallo (the fourth-generation of the oldest Sicilian familyengaged in viniculture), along with his wife Gabriella and their sonsJosè and Antonio. The name Donnafugata (literally “fleeingwoman”) refers to the story of Queen Maria Carolina of Austria,wife of Ferdinand IV of Bourbon. The Queen fled the court ofNaples on the arrival of Napoleon’s troops at the beginning of thenineteenth century to take refuge in Sicily, in the Palazzo Filangeridi Cutò in Santa Margherita Belice. It was the writer GiuseppeTomasi of Lampedusa in his novel The Leopard, who first employedthe name Donnafugata to refer to the palace at Santa Margherita andthe countryside estates of the prince of Salina, home today to thecompany’s vineyards. This adventure was the inspiration for theimage of the woman’s head with her hair blowing in the wind, whichappears on each bottle ofDonnafugata ‘Mille e una Notte’ wine.Donnafugata’s entire current production comes from 328 hectares(810 acres), 260 hectares (642 acres) of which are located at ContessaEntellina. The other 68 hectares (168 acres) are located onPantelleria. Overall sales in 2007 amounted to 16.7 million Euros,of which about 25% came from exports. Donnafugata’s technicalstaff boast fields of expertise that are wide and varied, yetcomplementary. The team includes an oenologist, an agriculturalscientist, a chemist and a biologist, as well as numerous sectorspecialists who act as consultants. It is truly a mix of proficiencies,which blend together to give life to an excellent wine.

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Above: Night harvesting (here,by machine) helps to decreasefermentation of the grapesduring transportationExperience and capability havealways been an added bonus atDonnafugata. Donnafugata’smanagers, right, are Giacomoand Gabriella RalloBelow: Graphic design forproduct label

Donnafugata’s estate in Contessa Entellina islocated in the province of Palermo, in the heart ofwestern Sicily, where vineyards have been an integralpart of the landscape for thousands of years. Heregrow not only native varieties (Ansonica, whiteCatarratto, Nero d’Avola, red Perricone), but alsointernational variants (Cabernet Sauvignon, Merlot,Chardonnay) that have demonstrated their abilityto adapt to the characteristics of the territory. Syrahand Viognier were also added in recent years, givinglife to two new wines in 2006: the white Polena(Catarratto, Viognier) and the red Sherazade (Nerod’Avola, Syrah). Contessa Entellina was establishedas a DOC (Denominazione di Origine Controllata,the Italian category of quality and origin assurance)in 1994 on the initiative ofDonnafugata.Donnafugata has managed an agricultural estateon the island of Pantelleria since 1989. It consists of68 hectares (168 acres), planted with the Zibibbovarietal (a variety of Muscat of Alexandria). Theopening of a new winemaking cellar in 2006 haspermitted Donnafugata to process the Zibibbograpes in a manner that allows respect for thedifferent viticultural norms from which the grapesderive – variations of altitude, sun exposure and ageof vine. In fact, the different batches of grapes canbe processed separately in the cellar until the finalmixing. Some of the Zibibbo vines on Pantelleriaare over a century old.Lastly, the Marsala cellars, built in 1851, are todayhome to a solid enterprise targeted towardsexcellence. It is here that the output fromPantelleria and fromContessa Entellina converge forrefining and bottling. The processes in the cellaruse simple technology and are always respectful ofthe intrinsic qualities of the musts and of the wines.The structure is equipped with insulated,temperature-controlled environments, in order toobtain the maximum energy savings possible, in linewith the company’s policies regarding theenvironment.

Donnafugata’s philosophy in the search forquality and attention to detail has made it one of thekey players of the Italian wine renaissance.“The production process now follows standards

that are recognized internationally,” Rallo explains.“The objective has become that of preserving theproduct and the tradition that are linked to a brandin a way that will exalt it. Everything relies on thevineyards, on the cultivation phase. In the cellar, theproduct can only get worse, not better. Today, allquality cellars rely on systems for temperaturecontrol; the new frontier is research in the vineyard.”A number of projects, mostly supported by localinstitutions, aim to select the best of the nativevarieties. Thanks to genetics, it is possible to selectthose plants most suitable for producing the desiredquality. In Sicily currently there are mass selectionsof Nero d’Avola and, on Pantelleria, of Zibibbo.Some experiments are also giving life to a few clonedselections, where each plant has the same DNA.“Thus far in Italy, we concentrated more on thelarger grape, on the bigger bunch, because this typeof culture gave better results and the quantity wasconsidered more advantageous economically,” Ralloadds. “Today, however, even the small grape can besynonymous with quality and consequentlysuccessful for a company in the wine sector. Cloneselections are made by institutes or universities; thecompany does not have the resources to carry out


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Respect for theenvironment andpromotion of theterritory are values inwhich Donnafugatabelieves and find theirmaximum expressionon Pantelleria

this type of research. Consequently, we have to relyon programs funded by public agencies, attemptingto collaborate with them during their research andgranting access to the soil for testing.”Another avenue being pursued by research centersis that of ’micro-winemaking’. These are helpful formaintaining as much data as possible, and thenrefining the production process on a larger scale. Itis, after all, experimentation that allows forimprovement and preservation of quality.Donnafugata appears to have understood this forsome time now: they did not hesitate before makingtheir land available for testing these new techniques.“We’re waiting for the conclusions of the research

so we can plant an experimental vineyard,” Rallosays. “Last year, our investments in new vineyardsequaled approximately 20% of sales, which are 16.7million Euros.”

The success of Sicilian wine is, in short, entirely due to the qualityof the vine, which preserves its properties. The other factors thatdetermine the final result are the irrigation methods, pruning, andthe choice of timing for the harvest. ”In this case,” Rallo concludes,“we rely on the chemical analysis of the must, but also on thesensory characteristics, of the taste of the grape.” Since 1983, thecompany has promoted an intelligent use of cooling technology forthe control of temperature in fermenting the must. It was decidedto cool the grapes to 10°C (50° F) to prevent volatilization of thearomas during the pressing phase. This remained the case until1998, when harvesting the Chardonnay by nighttime was first triedin an effort to avoid risk of undesired fermentation duringtransportation from vineyard to cellar. This also allowed savings of70% of the energy used for refrigerating before soft pressing. Nightharvesting is now one of the feathers in the company’s cap, not onlybecause of the publicity it attracts, but also for the beneficial effectit has on the final product.“For white grapes, the night is the best time to harvest,” Ralloexplains. “During the summer we have a temperature difference ofabout 16°C (60° F) between day and night, so this method makes itpossible to save a lot of energy. This way, we actually favor theproduct’s natural sedimentation and avoid the spontaneousfermentations and oxidations that would occur at 30°C (86°F) duringthe day.”Donnafugata’s starlit harvests have enabled Sicily to take a place

beside winemaking regions that have even longer traditions, likeTuscany, Piedmont, or the Veneto. This is also due, in part, to thecompany’s innate ability to find new approaches to generatinginterest in wines and to pursue innovations in keeping with theleading market trends.Similarly, the company’s management has invested over the past

few years in the building of a new 1,600-square meter undergroundcellar, where the optimal climatic conditions will cut down oncooling costs. Construction was completed in Marsala in 2007.Donnafugata decided to invest in clean energy, installing the firstsolar power system in Contessa Entellina in 2002. Together with anew installation that will be completed at the end of 2008, this willcover 70% of the winemaking cellar’s energy needs. A solar panelsystem was installed on the roofs of the historic Marsala cellars in2007.



What does the wine of the future taste like? TheSagrantino wine from the Arnaldo Caprai vineyard hasbeen trying to answer this question for some years,experimenting with the effects of the predicted futureclimate around the company’s vineyards in Montefalco(province of Perugia). The effects of climate change thathave been forecast for the planet for the next fifty yearsare being researched on the vines, in an effort toanticipate the characteristics of future vintages. LuigiMariani is an influential agricultural meteorologistand lecturer at the University of Milan, who has beencollaborating on the company’s scientific research forsome time.Arnaldo Caprai’s research program is the only one of itskind in the world, involving a simulation of the effectsof climate-induced overheating of the vines. The vinetrellises are covered with fabric to increase thetemperature of the plants. An aluminum mirrorincreases the amount of solar radiation the plantsreceive, which influences the process of photosynthesis.With this analysis, the company reaffirms its commitmentto the research that has always been an integral part ofthe company. That it is an “enlightened” company wasrecently testified to by their decision to print a series offamous quotations about wine on the corks of the bestbottles of Sagrantino. As Pascal once said, “There is morewisdom in a bottle of wine than in all the books thatmen have written.”

Arnaldo Caprai emphasizesthe vines’ origins and the

environment where they grow.The grower’s respect for

territory inspires a work ethicthat is mindful of the local

Montefalco ecosystem

A WINE THAT TASTESOF THE FUTURE



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Arnaldo Caprai is currentlyheaded by Marco Caprai, whoaccepted his father’s offer to takeover the family business in 1998,shortly after receiving his degree inpolitical science. The estate wasalready a recognized leader in theproduction of Sagrantino diMontefalco wine, a prestigious redwine made with Sagrantino grapes.For over four hundred years thisvariety has grown only in theMontefalco area. In 1990, there wereonly 400,000 bottles sold. Today,thanks to continuous investment inresearch and innovation, the salesproceeds have more than doubled –something which is almostexclusively attributable to theproduct’s quality.In 1970, there were fewer than 10

hectares (25 acres) of Sagrantinovines left; today, there are over 700hectares (1730 acres). “When I choseto take over the company, only twoyears had passed since the methanolwine scandal: dozens were poisoned,19 died, it was a huge blow to thesector,” Marco Caprai says. “Today,by contrast, Italy produces 37% lessthan it did at that time but thequality has increased dramatically.”At that time, Caprai and hisassociates began to survey theSagrantino vines that had survived inthe Montefalco area, and thenmoved on to cloning. The work wascarried out in collaboration with theAgriculture Department of the StateUniversity of Milan and care wastaken to preserve the differentvarieties. Since then, about 30hectares (74 acres) have beendedicated exclusively to research.Every year, 3% to 4% of profits arereinvested into experimentation,particularly toward the developmentof native varieties.

Over the last decade, Arnaldo Caprai has devoted resources to the research of genetic modifications to its grapes torealize a strain that produces quality wine but retains the variability that is the natural characteristic of a vine.It remains committed to the pursuit of innovation and research in the agronomic and enological sector and to

communicating the culture and identity of its region... while supporting the local environment



Arnaldo Caprai has been apioneer in the development ofcloning techniques to maximisethe quality of the Sagrantinogrape

From 1990 to 1993, the companyresearched the typical productionareas of the vines (Montefalco,Bevagna, and Gualdo Cattaneo),attempting to identify the plantsthe Sagrantino variety had comefrom. The project was carried outin conjunction with the Universityof Milan’s Agriculture Department(Istituto di Coltivazioni Arboree)and the Umbria Sitech TechnologyPark.This search for the progenitor

plants enabled the greatest possiblerecovery of the natural variety thathad been lost through previousmass selections. Presumed cloneswere derived from these progenitorplants and, in 1994, experimentalplots were started with this materialin two climatically different zones.After having mapped the DNA tocheck for possible similarities ordifferences, the grapes of the cloneswere subjected to the micro-winemaking process at the AgrarianInstitution and Wine Academy ofSan Michele all’Adige (IstitutoAgrario di SanMichele all’Adige) inthe province of Trento. Thecharacteristics of the resultant wineswere evaluated, in order to identifythe most interesting group of clonesfrom the point of view of improvingthe quality of the Sagrantino grape.Over the last decade, muchadditional effort was devoted to aproject for genetic improvement byclone selection, in order to obtain aquality wine while maintaining thevariability characteristic of thisvarietal.This initiative was intended to

select and propagate the plants thatcould best satisfy productionrequirements, as well as the rigidparameters established by the

DOCG standard. As a part of thisbroad program for the geneticimprovement of the Sagrantinogrape, a project was initiated in 1998to study the genetic variability ofindividual plants obtained fromseeds present in clusters of ripeninggrapes, and thus originated througha process of natural self-fecundation.Self-pollination, in the firstgenerations, produces an increase ofthe variability and the appearance ofnew morphological characteristics,such as compactness of the bunch

and the genetic makeup of certainproductive characteristics of thegrapes. This technique made itpossible to isolate several interestingcharacteristics, not only relating tothe quality of the product but alsoto other aspects that are morestrictly agricultural. Future studywill make it possible to evaluate theample variability that still is presentbut not yet expressed, making useof a modern method of geneticimprovement respecting biodiversityand naturally occurring selection.



MACHINESFOR TRAVELING SNO T J U S T

The automotive industry accounts forapproximately 11% of Italy’s gross domesticproduct and 9% of its exports. The sector consistsof 275,000 employees, which becomes 400,000when salespeople and technical supportpersonnel are included. It is Italy’s leading privatesector in terms of research and developmentinvestments, with 2.5 to 3 billion Euros yearly.According to a survey by the National Instituteof Statistics (ISTAT), there are altogether 38mechanical industry districts, areas where a“community of people and a population ofindustrial companies are mutually integrated.”Seventeen are in the northwest, 16 in thenortheast, 4 in central Italy, and one in southernItaly. Of particular interest is themechatronics, or‘hi-mech’, district in Emilia Romagna, whichincludes 28,000 companies who rely on 30university departments for research anddevelopment.

Ferrari, Lamborghini,Maserati, Ducati – allare status symbols representing pinnacles ofexcellence. Altogether, 1.28 million vehicles werebuilt in Italy in 2007, the same year Fiat becameone of the world’s top ten producers.Italy’s component production sector, made upof 2,800 companies and with overall sales of 46billion Euros, has a leading role. Europe is itsprincipal market but, in recent years, easternEuropean countries, such as the Czech Republic,Slovakia, and Poland, have also affirmedthemselves as competitors. The ”Made in Italy”brand plays a key role.“It is important to keep Italy’s research and

development centers because they contribute asignificant slice to added value,” says EugenioRazelli, president of ANFIA (the NationalAssociation of Automotive Industry Companies).“Companies such as Marelli, Pirelli, Brembo,Cobra, and Landi are on the cutting edge in

innovative sectors that research ways to reduceconsumption and carbon dioxide emissions.And active safety is also a new frontier.” Italianexcellence also travels on two wheels.“Technology, design, and craftsmanship are the

three characteristics that make our bicycles andmotorcycles part of the world’s collective idea of‘Made in Italy’,” observes Constantino Ruggiero,director general of ANCMA (the ItalianMotorcycle Manufacturers’ Association).The Italian nautical industry is at the cutting

edge of R&D and can rely not only on itstraditional ‘culture of the sea’, but also on thetechnician’s and craftsman’s knowhow, which isencountered all the way up and down thepeninsula.There are 25,000 workers involved in theshipbuilding industry, including shipyards,accessories, and engines. Over the last two years,the nautical sector grew by 25%.

CHAPTER3.1



S T Y L E , B U T E NG I N E S


THE STORIES

MICRO-VETT

DAINESE

DALLARA

DUCATI

FERRETTI

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he latest technological challengeforMicro-Vett is a prototype fora three-wheel electric scooter,provisionally called “Moose.”The body line and chassis wereconceived by the engineers anddesigners of the Exnovo studioin Rimini. The same studioprovided research on functionaland dynamic aspects, such as theoscillation and inclination of the

rear wheels, which must be able to ensure stabilitywhile turning. It carries lithium batteries, whichare stored under the seat. Current performancestatistics indicate an average life span of 150,000kilometers (over 90,000 miles) with approximately1,500 recharges.Since 1986,Micro-Vett has produced more than5,000 electrical and hybrid vehicles, starting withthe models of three Italian companies (Fiat, Piaggio,and Iveco) and developed in collaboration with localand international research centers. Based in Imola(Emilia-Romagna region), the company’s 2008 salestotaled 15 million Euros, twice the figure achieved

in 2006. Each year, its plant produces 700 vehicles,working their production line (12 pieces ofmachinery, including bridges and hoists) to 80% ofits capacity. The equipment for “in progress”control of components was developed within thecompany, as were the work cells for preparationand control of batteries and cabling. “These aretechnologies that make the difference between usand our competition,” says Micro-Vett vicepresident Massimiliano Di Gioia. Of the 45employees, ten work in R&D activities. The teamhas obtained type approval for a wide array ofvehicles suitable for the needs of private, public,and commercial transportation.The Porter Electric, for example, is the top sellingelectrical vehicle in Italy. Purchased by some 350clients throughout the world, its customers includePoste Italiane (the Italian postal service),Disneyland, and DHL. The Iveco Daily is the mostwidely used vehicle for commercial transport onthe peninsula: Micro-Vett’s Daily Bimodale vancan transport up to a ton of cargo and is alsoavailable as a 22-seater school bus, or as the Combiversion.

TAQUESTIONOF PROTOTYPES

Micro-Vett is immersed in the Emilia-Romagnamechatronics district: an ensemble of small- andmedium-sized companies specializing in design andproduction of components for the automotive in-dustry.Zapi, one of the suppliers for the Imola-basedcompany, was established in 1975 in Poviglio(Reggio Emilia province) and now employs 350people. In 2007, it produced 350,000 controllers and200,000 inverters, attesting to its leadership positionon a European level.The technological heart of the area is made up ofa network of about ten excellent laboratories,linked with the University of Modena and ReggioEmilia, University of Bologna, University of Parma,University of Ferrara and to other domesticresearch centers, such as Italy’s National ResearchCenter. “Zero emissions means energy savings:

while the efficiency of an endothermic (traditionalreciprocating) engine is 21-22%, electric engines canreach as high as 80-90%,” reports Micro-Vettpresident Gaetano Di Gioia.The most receptive markets in Europe for electricvehicles are Spain, France, and the Scandinaviancountries.Micro-Vett can rely on projects for sustainabletransport in nearly every region of Italy. The Cityof Reggio Emilia, for example, purchased 371electric vehicles, which it uses for publictransportation, administrative activities, andhomecare assistance. The City of Bergamo has 140;it uses them for public space maintenance andother services. Urban centers in southern Italy havealso shown an interest in electric vehicles: Cataniabought 22 for maintenance services, and Lecceacquired 34 for city cleaning needs.

EMILIA-ROMAGNA AND MECHATRONICS

Micro-Vett’s technology was at the forefront of an award-winning mobility project inReggio Emilia, where nearly 400 electric vehicles were traded for traditional motors to

improve the region’s air quality and lower costsSince then, other European cities including Stockholm have followed the council’s lead in

the deployment of electric commercial vehicles to protect the environment

124


THESTORIES

M I C R O – V E T T

125

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Dafety and comfort: theInfinity helmet allowscommunication betweenseveral bikers on a grouptrip without the need forexternal devices. Within a400-meter (1,300-foot)radius, up to three peoplecan talk together and thereception is theoreticallyunlimited. The “road use”

interphone is coupled with a Bluetooth systemthat allows connection to a cell phone: you justpress a button on the outside of the helmet toanswer incoming calls or get GPS directions.“By the end of 2007, 600 helmets in the betatest phase had been sold,” said AndreaAmbrogi, manager for the Infinity project.“Customers’ recommendations helped us toimprove signal quality and battery life.” Aleading company in sports apparel and safetyequipment, Dainese had sales reaching 108million Euros by the end of 2007. Themotorcycle division produces 70% of the sales,but proceeds fromwinter and water sports andmountain biking are also increasing.Dainese , which was established in 1972 in

Vicenza (region of Veneto), produces 5,000articles of clothing each year. They were thefirst in the world to launch protective gear formotorcyclists and, in subsequent years,introduced advanced materials like Kevlar andcarbon fiber. The company is concerned aboutthe environment. The eco-friendly “whitetanning” process employed for producing their“LTD1” jacket avoids use of formaldehydes orheavy metals like chrome.

SKEEP AN EYE

ON THAT HELMET!

The company studied the ergonomics of suits for motorcycle riders in the correct saddleposition and derived the concept of composite protection, based on the body parts to beprotected. Its first back protector offered spinal protection for riders, but as riding styles

changed, knees were the most at risk from scraping along the ground

Its T-Age suit was the first leather suit to win the acclaimed ADI Compasso d'Oro GoldenCompass design award

Later the company’s signature aerodynamic hump, the culmination of several phases ofinnovative design, was modified to fit Dainese’s patented airbag

126

291305.P100-143:Excellence 8/28/09 9:57 AM

D A I N E S E

THESTORIES


291305.P100-143:Excellence 8/28/09 9:57 AM


The cutting of fabrics is increasingly making use ofavant-garde technologies. Teseo, for example, is amachine that is able to cut several different materialcolors at once, a feature thatmakes it ideal for clothingto be produced in limited series. It was built by anItalian company based in the region of the Marche,known for its manufacturing vocation. Teseo S.r.l.was one of the first companies in the world to launchCAD (computer assisted design) software forfootwear; it now markets CAD/CAM systems in 61countries. The first action after the cutting ofmaterialsis the finishing of the leather. Next comes theperforation phase, an operation that makes the articleof clothing more resistant but without sacrificingbreathability. The machinery used by the companycan perform either total perforation (meaning on theentire piece of leather) or localized perforation, whichmakes use of a system patented byDainese. Ensuingprocesses include hot stamping and laser cutting andembroidering of elastic bands. The assembly of thearticle, on the other hand, is organized around a “workcell” structure: the workers are each specialized in thetreatment of a single portion of the model, thusimproving efficiency (by increase of deftness and speedof movements) and quality.The entire production process atDainese is driven bythe philosophy of Kaizen, a Japanese word thatmeans“continuous improvement”. The company has nowarehouses for intermediate storage along theproduction path. Internal flows are optimized, whichfacilitates a leaner structure because workers’ wait timesand movements are minimized. The Kaizen methodis also adopted in quality control procedures.

Dainese’s Headquarters inVicenza, Northern Italy(Photo Paul Warchol)

On the right, manager LinoDainese

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Dainese’s first helmet design,Ergon, was later translatedinto a product for other high-impact sports, such assnowboarding, skiing andkayaking

Embroidery machine at work

Dainese has 450employees in total,including 133managers and120 productionworkers. ItsR&D center, “D-Tech”, islocated in Molvena(province of Vicenza). The54-member teamcollaborates regularly withthe Polytechnic Universityof Milan and withCEFRIEL, the technologytransfer institution. Thecompany’s distributionnetwork is worldwide, withmore than 2,300 stores, ofwhich 200 are “shop-in-shops” - dedicated sectionsin department stores. Fiftyare single brand franchisesand a dozen are directlymanaged flagship stores,called “D-stores”. Thecommunity of Daineseenthusiasts meets online atthe D-club website: thereare 41,000 registeredmembers and thecompany’s web pagesregister over 8 million hitsa month.

291305.P100-143:Excellence 8/28/09 9:58 AM

D

Dallara’s two wind tunnels occupy a surfacearea larger than Milan’s famous San Sirostadium. Technicians use them to test carsusing scale models that are anywhere from40 to 60% of original size. The structureswere built by Dallara, a leader in designingand producing cars for Formula 3, theAmerican IndyCar Racing League, the GP2series, and single brand championships.Founded in 1972 by engineer GiampaoloDallara after key experiences with Ferrari,Maserati, and Lamborghini, the company’syearly sales now top 56 million Euros. Itsheadquarters is at VaranoMelegari (provinceof Parma), among Emilia-Romagna’s extensivenetwork of companies specializing inmechanical industries.The creation of new vehicles requires thecreation and development of four virtualmodels on a computer. The first is theaerodynamics test: it unites information fromthe wind tunnel and CFD (ComputationalFluid Dynamics), specialized software fordisplay and analysis of extremely detailedroad test data. The next pass involves asimulation on the world’s circuit tracks.Analysis of the automobile data allowsoptimizing design toward achieving the bestmean performances during races. Afterstructural calculations and crash testsusing the third virtual model, the fourthphase uses Pro/Engineer software to createthe final design.

Dallara designs in 3D using the most advanced computer-aideddesign softward to build a fully integrated 360-degree model tounderstand how the prototype will look and perform prior to

manufacturing any component. It is a flexible approach that allowsfor the rapid incorporation of design changes without costly overruns


DESIGNING


D A L L A R A

THESTORIES

131

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“We are so confident in our designs that we move directly toproduction of the cars, without making prototypes. This year, webuilt 60 cars for the Formula 3 before we ever even started a singleone up,” says Dallara CEO Andrea Pontremoli. Sixty aerospace,aeronautical, and mechanical engineers work in the company’s R&Dlab. Among them we find Dialma Zinelli, recipient of Oxford’sprestigious World Motorsport Symposium Award for RacecarAerodynamicist. There is also close collaboration with Italianacademia. Crash tests for the chassis are performed at thePolytechnic University of Milan and the wind tunnel test area wasdeveloped in collaboration with the University of Pisa. Dallara has180 employees altogether. As well as those with college degrees, one-

third are upper/secondary graduates or expert technicians, and theremainder are highly specialized workmen, such as assemblers,laminators, or metal carpenters.The VaranoMelegari area has a certain peculiarity: the top “Madein Italy” automobile brands; Ferrari, Lamborghini, Maserati, andDucatiare all there, located within a radius of a few hundred miles.“Each company is both supplier and client to every other

company,” says Pontremoli.The contribution from the network of Italian suppliers is strategic.

For its carbon fiber composites, Dallara has establishedrelationships with companies like Carbon Dream (Florence), Camattini(Collecchio, just south of Parma) and Bercella (VaranoMelegari). The

THE CAR WITHOUT PROTOTYPES

Dallara’s facilities for designing, building and supporting the world’s mostcompetitive race cars rival those of many Formula 1 teams



five-axis milling machines are produced by Jobs, a 200-employee,Piacenza-based company that exports 80% of its machinery.Dallara’s scale models are produced using Italian-madestereolithography systems (a sort of three-dimensional printingsystem). In just 24 hours, they can create a high-precision model bymaking laser incisions on photosynthetic resin. Dallara has alsoadapted existing software to better suit its needs. Their ERP(Enterprise Resource Planning) system was developed with an open-source program, because the carbon fibers composites must be keptcool and may have an expiration date. From this perspective,Dallara’s supply chain thus unites requirements typically imposedby both the mechanical and foodstuffs sectors. Even the softwareused for calculating roundtrip lap time was developed in-house.Simulation of races on “virtual” circuits allows for modificationsbefore the cars are even built. Dallara sells 90% of its productionabroad: 40% is sold to the United States, 40% to other Europeancountries, 9% in Italy, and 11% in other countries, particularly Japanand Malaysia.

Dallara’s technology includes a vast database of track, windtunnel and R&D data to supplement CAD-generated virtual

designs in each phase of the pre-build process

133


D

ucati’s Hypermotard1100 is a gem for truetwo-wheel enthusiasts.Lightning accelerationand handling abilityunite with a 90horsepower engine togive a top speed of 220km/h (over 135 mph).It has been producingsporting motorcycles

since the 1950s. Established in Borgo Panigale(outside Bologna), Ducati is deeply rooted inEmilia-Romagna, the same region that gave riseto Ferrari, Lamborghini andMaserati.In 2007, Ducati passed the benchmark of40,000 motorcycles sold, achieving 397millionEuros in sales, which was an increase of 30%over the previous year. Its range is aimed at anumber of different market segments:Superbike, Desmosedici RR, Monster,Multistrada, SportClassic, and Streetfighter.Added to its sales in the motorcycle sector, thecompany is also successful in marketing spareparts, accessories, and apparel.

DTECHNOLOGYON THE TRACK

Above and on the right, Ducati’sclassic Hypermotard



D U C A T I

THESTORIES


291305.P100-143:Excellence 8/28/09 10:31 AM


The Hypermotard project clearly illustrates thetechnological excellence of the Italian automotiveindustry. Using 45-mm diameter throttle bodies, theinjection systemwas designed byMagnetiMarelli, aworld leader in the areas of powertrains, lighting, andelectronic systems. With 27,000 employees and 9research centers, the group’s yearly sales have reached5 billion Euros.Hypermotard’s front suspension, consisting of a 50-

mm upside-down fork with an anti-frictioncarbon-based coating, was developed by Bologna-basedcompany Marzocchio, which specializes in suspensionsystems for two-wheel vehicles. The forged light alloyrims were created by the Varese-based companyMarchesini. They are considerably lighter than usual,which reducesmoment of inertia and unsprungmass.For braking, the Hypermotard relies on radiallymounted 4-piston calipers on the front discs and onthe rear monodisc designed by Brembo, a Bergamo-based world leader in braking systems. Brembo alsosupplies braking systems for vehicles in the Formula 1andMotoGP championships.

Ducati's engines arebuilt on a reputation

not just forengineering: their

sound will identify aDucati bike even before

it appears



The R&D sector is strategic forDucati. It employsnearly 200 people ranging from certified techniciansto engineers, supported by an investment of 7% of salesproceeds. Eighteen to 24 months may pass fromoriginal conception of a new motorcycle project, tothemoment when the product appears in stores. Theevolution of the vehicle is precise and meticulous,down to the smallest detail. After analysis of theclientele’s needs and meetings with the marketingdepartment, R&D technicians create two-dimensionaland three-dimensional sketches. Next, a life-sizemodel is created and undergoes an engineering phase,using three-dimensional models developed by CADsoftware. The next stage is the creation of a prototype.Finally, after functional testing of the vehicle,production can begin.With the help of the Internet, the company’s rapport

with clientele and enthusiasts is constant. OnDucati.com, the community of users can expressthemselves, propose ideas and discuss any and alltopics relating to motorcycles, Ducati bikes inparticular.“On the website, we find suggestions and ideas every

day,” saysmarketing director, Andrea Sgorati. “We haveto knowhow to listen to both strong andweak signals,and how to interpret them. For example, as wemovedfrom prototype to production of Hypermotard wetook advice we received on the aesthetics and the valueof the product very much into account.” Twelvemillion people visited Ducati.com in one year andthere are 250,000 registered members in the onlinecommunity. Ducati exports 75% of its production.Sales have increased dramatically in Great Britain(36%), Germany (10.7%), Italy (10.4%), in northernEurope (27.7%), and in the United States (22.4%).

RESEARCH AND DEVELOPMENT

The uniqueness of the Ducati brand is the result of somevery specific technical solutions: the desmodromic engine

valve control system, the tubular steel trellis frame and theL-twin cylinder engine

291305.P100-143:Excellence 8/28/09 10:01 AM


FMochi Craft’s Long

Range 23, the world’sfirst hybrid propulsionyacht measuring over20 m (over 65 feet),was designed at the

AYT (Advanced YachtTechnology) center,

Ferretti Group’sengineering division.Two banks of lithium

ion batteries locatedin the engine roomcan substitute for thediesel engine. The

boat can leave port,enter into protectedareas, and navigateclose to the shoreline

without polluting.

THE YACHT IN THE LAB

The Ferretti 90’ Pershing

291305.P100-143:Excellence 8/28/09 10:02 AM


F E R R E T T I

THESTORIES

291305.P100-143:Excellence 8/28/09 10:02 AM


“The Hybrid propulsion system is already presetto be able to use hydrogen fuel cells as soon as thosebecome available on the consumer market,” AYThead Andrea Frabetti explains. In recent years theFerretti Group team, composed of 90 engineers,architects, and technicians, has also developed otherstrategic innovations. The Fer.Wey (Ferretti WaveEfficient Yacht) hull, for instance, ensures greaterstability for the craft because of reduced waterresistance from the hull and the absence ofvariations in the trim.Ferretti Group celebrated its first 40 years ofbusiness in 2008. It now has around 3,000employees and a production value of over 1 billionEuros. The Group’s nine brands (Ferretti Yachts,Pershing, Itama, American Bertram, Riva,Apreamare, Mochi Craft, Custom Line and CRN)offer a wide array of types, including flybridge,open, “gozzi sorrentini,” lobster, sport fisherman,and mega-yachts.The most important piece of machinery used inproduction of every Ferretti craft is the “Poseidon,”a five-axis pantograph. It is one of the largest andmost advanced in Europe and is designed forproduction of the wood models of all new vessels.Equipped with cutting-edge technology that cansatisfy the growing demand for increasingly complexshapes, the machine’s dimensions allow forproduction of hulls for boats as long as 30 meters(almost 100 ft). The Poseidon system was designedspecifically for Ferretti by CMS S.p.A.(Construction of Specialized Machinery) located inZogno (province of Bergamo).CMS specializes in the production of

Ferretti’s long range Mochi craft, right. Its ARG (AntiRolling Gyro) technology, developed with Mitsubishi HeavyIndustries, helps to decrease roll and guarantees maximumcomfort during cruising; the "Smart Command" Easy Dockand Auto Troll of ZF assures maximum control of the vesseland the management of the integrated system of the Gi8 andNAVIOP enables total control of the yacht operations from asingle screen.

291305.P100-143:Excellence 8/28/09 10:03 AM


specialized in sectors complementary to nautical.Zago S.p.A. designs and produces furnishings for thenautical sector, especially for yachts over 100 feet.Another Forlì company, Diesse Arredamenti S.p.A.,provides furnishings for watercraft, as well as forhotels, pharmacies, and public spaces. For its glass-reinforced plastic (fiberglass) components, FerrettiGroup calls upon Resin Sistem in Fano (region of theMarche).Ferretti Group’s distribution system is active in

80 countries, with a network of over 85 dealers whoguarantee clients the highest quality services inmarinas throughout the world. Europe and theUnited States represent steady markets, but theGroup is also present in Asia, with a representativeand promotional office in Shanghai.

thermoforming machines, cutting robots, and water-jet cutting systems that are used in the constructionof space shuttles, military and civilian aircraft, andFormula 1 racing cars, as well as yachts. Seventypercent of CMS’s sales derive from exports. Besidesthe Poseidon, other machining centers such as theAres, Cronos, and the Mbb and Fxb, representavant-garde technologies for working aluminum,light alloys and composite materials.In the Ferretti Group, all phases are performedwith great attention to detail and continual strivingfor maximum quality, from design, to theengineering, to production, and on to final testing.But Ferretti, located in Forlì (province of Emilia-Romagna), can also rely on added value from othercompanies of the Ferretti Group that are highly

Right: Ferretti’s 92’ Riva‘Duchessa’. The Ferretti five-axis pantograph is the templatehull for all its yacht designs,one of Europe’s most advancedfor the crafting of wooden ves-

sels of varying sizes



ACIMAC – ASSOCIATIONOF ITALIANMANUFACTURERS OFMACHINERY AND EQUIPMENTFOR CERAMICS

ACIMALL – ITALIANWOODWORKINGMACHINERY AND TOOLSMANUFACTURERS’ASSOCIATION

ACIMGA – ITALIANMANUFACTURERS ASSOCIATIONOFMACHINERY FOR THE GRAPHIC,CONVERTING AND PAPER INDUSTRY

ACIMIT – ITALIAN TEXTILEMACHINERY ASSOCIATION

AMAFOND – ITALIAN FOUNDRYMACHINERY AND PRODUCTS ASSOCIATION

ANCMA – NATIONALMOTORCYCLEMANUFACTURERS’ ASSOCIATION

ANFIA – ITALIAN ASSOCIATIONOF THE AUTOMOTIVE INDUSTRY

ANIE – ITALIAN FEDERATIONOF ELECTROTECHNICAL AND ELECTRONIC INDUSTRIES

ASSOBIOTEC – NATIONAL ASSOCIATION FOR DEVELOPMENTOF BIOTECHNOLOGY

ASSOCOMAPLAST – ITALIAN PLASTICS AND RUBBER PROCESSINGMACHINERY ANDMOULDSMANUFACTURERS’ ASSOCIATION

ASSOFOODTEC – ITALIAN ASSOCIATIONOFMACHINERY AND PLANTMANUFACTURERSFOR FOOD PRODUCTION, PROCESSING AND PRESERVATION

ASSOMAC – NATIONAL ASSOCIATIONOF ITALIANMANUFACTURERS OF FOOTWEAR,LEATHERGOODS, TANNERYMACHINES AND ACCESSORIES

CONFINDUSTRIA - ITALIAN CONFEDERATIONOF INDUSTRY

CONFINDUSTRIAMARMOMACCHINE – ITALIAN ASSOCIATION FOR THEMARBLE ANDSTONEMACHINERY INDUSTRIES

FEDERCHIMICA – ITALIAN FEDERATIONOF CHEMICAL INDUSTRY ASSOCIATIONS

FEDERMACCHINE – NATIONAL FEDERATIONOF ASSOCIATIONS OFMANUFACTURERS OFCAPITAL GOODS INTENDED FOR INDUSTRIAL ANDHANDICRAFTSMANUFACTURINGPROCESSES

GIMAV – ITALIANMANUFACTURERS’ ASSOCIATIONOFMACHINERY, ACCESSORIES ANDSPECIAL PRODUCTS FOR GLASS PROCESSING

UCIMA – ITALIAN PACKAGINGMACHINERYMANUFACTURERS’ ASSOCIATION

UCIMU–SISTEMI PER PRODURRE – ASSOCIATIONOF ITALIANMANUFACTURERS OFMACHINE TOOLS, ROBOTS, AUTOMATION SYSTEMS AND ANCILLARY PRODUCTS

UNACOMA – NATIONAL UNIONOF AGRICULTURALMACHINEMANUFACTURERS

We thank the followingItalianManufacturing

Associations

LIST OF ASSOCIATIONS



ACQUA DI PARMAACS DOBFARAERMACCHI

ALENIAALFA ROMEO

ALGIDAANNAPURNA

ARNALDO CAPRAIARTEMIDEARTSANA

ATOMAGUSTA

AVIOBARILLA

BERCELLABIESSE

BIOXELLBISAZZA

BMBBOZZETTO

BRACCOBREMBO

BUSELLATOCAMATTINI

CANDYCARBON DREAM

CARRIERCART D’OR

CEFLACMS

COBRACOLOROBBIA GROUP

COMAPSUDCOMELZ

COMERSONCOMEZ

COMI CONDORCORMATEXCOSMINT

COSMO PHARMACEUTICALSCOTONIFICIO ALBINI

COTTO D’ESTECRIPPA

DAINESEDALLARADELL’ORCO VILLANIDELMACDIASORINDIESSE ARREDAMENTIDOLCE & GABBANADONNAFUGATADUCATIELBO CONTROLLIELECTROLUXELICA GROUPERMENEGILDO ZEGNAEURALPHAFAGORFAVAFENZIFERRAGAMOFERRARIFERRETTI GROUPFIATFIMEFOOD VALLEYFRAMESIFRATELLI GUZZINIGAIOTTO AUTOMATIONGENTIUMGEOXGIUGIARO ARCHITETTURAGOTHA COSMETICSGRANITI FIANDREGRUPPO LVMHGRUPPOMARZOTTOGRUPPOMOSSI & GHISOLFIGUCCIGUTMANNIGVILLYCAFFÈIMAINDENAINDESITINTERCOSIVECO

JOBSKARTELL

KERAKOLLLACMA ANTIPIOL

LA CREMERIA MOTTALAMBERTI

LAMBORGHINILANDI

LINIFICIO E CANAPIFICIONAZIONALE

LONATILORIS BELLINILORO PIANA

LOSMAMAC PHARMA

MAGNETI MARELLIMANETTI & ROBERTS

MANFREDONIA VETROMAPEI

MARAZZIMARCHESINI

MARELLIMARZOCCHIO

MARZOCCHI POMPEMASCARA PLUS

MASERATIMASMEC

MEDITERRANEAMERCK SERONO

MERLONIMICRO-VETT

MOLMEDMONTEDISON GROUP

MOTOMANNEGRI BOSSINEW LASTNEWRON

PHARMACEUTICALSNEXT TECHNOLOGY

TECNOTESSILESocietà Nazionale

di Ricerca r.l.NICOX

NOVAMONT LABORATORIESOBEMOCMIPAVANPIAGGIOPIBERPLASTPIDIELLEPIRELLIPONZINIPRÉNATALPRIMA INDUSTRIEPROMATEC GROUPRADICIGROUPRAGNORANARESIN SISTEMRIELLOROEDERROMAGNOLOROSSI E CATELLISACMISCMSILVIO MORASINTERAMASITI- BTSOCIETÀ COSMETICISORINSTORCISYNBIOTECSYSTEMTESEOTOÈTORIELLITYCON TECHNOGLASSUNITECHVACCAI & BOSIVEGA INTERNATIONALVIBRAMWHIRLPOOLXEPTAGENZAGOZAPI3V COGEIM

LIST OF COMPANIES


291305.P100-143:Excellence 8/28/09 10:05 AM

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