Barilla's Flagship Pasta Plant Showcases Integrated Robotics

LGVs as conveyor alternatives

A key impetus of this renovation project was the wish to replace conveyors with LGVs for pallet transport within the facility, Spadini notes. “Traditional conveying systems are sized for production peaks and not flexible enough to manage variations in throughput, in terms of both flows and volume,” he says. “Therefore, pallet conveyor systems are typically highly inefficient."

The Parma facility uses three main types of LGVs—carrying a single pallet, two pallets, or four pallets at a time. The LGVs interact with floor-positioned pallets and AS/RS induction stations. They pick up and drop off pallets between receiving and manufacturing, palletizing, stretch wrapping, labeling, finished-goods warehousing, and staging locations for shipping. Roller beds on the LGVs allow efficient roll-on/roll-off.

The LGV roller beds allow an efficient roll-on/roll-off procedure.Photo courtesy of E80 Group

LGV navigation is based on target triangulation. Each LGV is equipped with a rotating laser that scans 360 degrees around the vehicle for laser targets mounted on columns, walls, and stationary machinery. The reflections from these targets are triangulated to determine position, and the position is compared to a CAD-type map stored in the LGV’s memory.

Parma’s LGVs employ lithium Flash Battery technology, which provide low toxicity, well-defined performance, and long-term stability.Photo courtesy of E80 GroupDeveloped for E80, lithium Flash Battery technology provides a high level of performance for industrial vehicles. The lithium iron phosphate delivers low toxicity, well-defined performance and long-term stability. Having a very constant discharge voltage, Flash Battery technology delivers virtually full power until the battery is discharged.

Integrated system controls

Running the LGVs, as well as all integrated robotics systems within the Parma distribution facility, is E80’s Smart Integrated Logistics (SM.I.LE80) controls platform. SM.I.LE80 continually updates the positional status of each LGV—including whether it is loaded or unloaded, emergency stopped or soft stopped, operating in manual mode, and battery level. An HMI screen gives the operator a graphical overview of the LGV locations in the system and monitors each in real time.

The SM.I.LE80 controls ensure the integrated and automated management of systems, communicating with AS/RS, palletizers, wrappers, and shipping staging locations. The entire LGV logistics flow within the Parma distribution operation can be centrally managed from this platform.

Six stacker cranes support 47,000 pallet locations.Photo courtesy of E80 GroupBarilla’s high-density automated warehouse—where six stacker cranes support 47,000 pallet locations—integrates perfectly with the LGV technology. E80’s AS/RS Crane Store systems are equipped with automatic product handling devices for double-depth storage. Because they can operate at heights of up to 130 ft, these systems significantly increase warehousing capacity. An additional 50,000 pallet locations are used for LGV drive-in high-density low-bay storage.

Pallet-free robotic palletizing

Barilla’s facility uses a unique palletizing process. Robotic palletizing stations form cases in palletized configurations directly on the palletizers’ platform. The configurations are then moved onto LGVs and transported to other end-of-line process stations in the facility where a pallet is inserted underneath prior to storage and shipping.

Robotic palletizing stations form cases in palletized configurations directly on the palletizers’ platforms, eliminating wooden pallets.Photo courtesy of E80 Group

This removes wood pallets from much of the operating area. “Removing wood from production and many distribution areas means removing an element that may pollute the environment where we produce and package our products,” Spadini points out. “But also, managing pallets without wood parts opens up the opportunity of handling and reprocessing of pallets in a completely automated way, improving efficiency and minimizing environmental impact.”

Barilla’s high-speed stretch wrappers employ automatic wrapping head changeovers, eliminating the need to stop production.Photo courtesy of E80 GroupAs with the other systems in the distribution operations, Barilla’s end-of-line stretch wrapping and labeling are also robotic and fully integrated with the LGVs and other robotic processes. The high-speed stretch wrappers employ automatic wrapping head changeovers, eliminating the need to stop production.

“We can manage not only very accurately the use of our stretch wrap film, but we have also reduced film usage by almost 30% compared to our prior stretch wrappers,” Spadini says.

Traceability

In addition to managing LGV traffic and the other integrated robotics systems, the SM.I.LE80 control system maintains control and identification of each case of products throughout the distribution facility. Once cases and pallets leave the facility, the labeled identification provides a tracking mechanism for complete track-and-trace throughout the supply chain.

“For Barilla, traceability means providing the right information, correct information, and timely information on all our products from the moment we received the lots of raw materials to the moment we actually distribute and display our products on shelves,” Spadini says. “Full traceability, for us, is one of the main elements to ensure and guarantee our consumers the right to nutritionally safe products and also controlled products.”