The customer aimed to increase pallet storage capacity, improve storage and retrieval speed, and optimize logistics processes while maintaining existing metal structures and complying with building and performance constraints.
Barilla, the historic Italian multinational founded in 1877 and a global leader in pasta, sauces, and bakery products, has launched an ambitious logistics modernization project at its Castiglione delle Stiviere facility in the province of Mantua.
With an annual production exceeding 1.9 million tons and a network of 28 manufacturing sites, Barilla chose to upgrade an existing, outdated structure by transforming it into a state-of-the-art automated warehouse, aligned with the company’s long-standing commitment to innovation and sustainability.
The project had two main objectives:
Entrusted to LCS, a specialist in intralogistics solutions, the project involved a complete revamp of the existing automated system, preserving the original steel structures and adhering to the building’s dimensional constraints.
In collaboration with Dalmine Marcegaglia for structural and civil works, LCS engineered a solution based on master shuttle technology with slave shuttles, enabling fast and precise pallet handling.
The new automated warehouse spans 40 meters in width, featuring a central aisle surrounded by five storage levels, totaling 400 deep storage channels (14 meters each). Pallets pass through weight and shape verification stations before being transported across the levels by master shuttles (traveling up to 240 m/min) and slave shuttles, which automatically deposit or retrieve pallets based on current orders, expiration dates, and inbound/outbound protocols.
The system handles 60 inbound and 60 outbound cycles per hour, ensuring a continuous and optimized goods flow.
Operations are managed by LogiWare, LCS’s proprietary software, which also controls the semi-automated warehouse on-site, providing full integration across operational areas and real-time supervision of all storage and handling activities.
Thanks to this upgrade, Barilla has increased its storage capacity by approximately 6,500 pallet positions, significantly reducing costs associated with shuttling and external storage, and transforming a previously underutilized area into a strategic asset.
This project exemplifies how the synergy between engineering expertise, advanced technology, and strategic vision can deliver tangible and lasting results, reinforcing Barilla’s position as a market leader and a pioneer in sustainable and innovative logistics solutions.
