Chiapparoli logistica

Silvano Chiapparoli Logistica, a leading company in pharmaceutical logistics, has undertaken a major innovation project at its Livraga (Lodi) site, partnering with LCS to implement a high-performance automated picking system. The goal was to enhance efficiency, speed, and flexibility in order fulfillment, strengthening market competitiveness and preparing for the demands of e-commerce logistics.

The project began with the order in July 2015, followed by installation in January 2016 and go-live in February of the same year.

LCS designed a tailor-made solution, fully adapted to the structural constraints of the existing building. The system includes:

• Mechanical components
• Carton sealing and closing machines
• Electrical control systems
• Automation and supervision software
• WMS software integrated with the client’s ERP

A key feature of the system is the classification of products by rotation index and shipping volume, divided into three categories:

• Class A+ (full cartons, high rotation): managed on pallets and picked via RF terminals
• Class A and B (medium/high rotation, medium/small volumes): stored in gravity-fed racks and picked using Pick to Light
• Class C (low rotation, small volumes): stored in traditional shelving and picked via RF terminals

The automated picking system has delivered significant benefits:

• Faster order preparation
• Streamlined operational flows
• Reduced picking errors

All storage types are organized around a central picking and carton handling system. The Pick & Pack process is guided by LCS’s WMS, which calculates the number and size of cartons based on order content. Each carton is assigned to an order at the start of the line.

In the Pick to Light zone, each item location features a display showing the quantity to pick. The zone picking method ensures high-speed execution during peak days, with operators working within a 5-meter zone, while on slower days, operators can cover multiple zones.

After picking, cartons pass through a weighing station to verify actual vs. theoretical weight. Any discrepancies trigger a rejection and manual check. Cartons are then automatically sealed, labeled with shipping address and packing list, and sorted by courier via a 10-exit sorter.

Technically, the 2016 system includes:

• 8 picking zones, each with 40-meter-long lines
• Weight control station with rejection for N.O.K. cartons
• 3 automatic sealing and labeling branches
• Sorter with 10 courier exits
• Use of LogiWARE (line management), LogiCON (supervision), and LogiTRASP (automation control)

The system handles 6 carton types and 1,400 SKUs, with 600 stored in gravity-fed channels for medium/high rotation items.

Thanks to LCS’s intervention, Silvano Chiapparoli Logistica has achieved a technological leap, improving operational efficiency, order speed, and flexibility, reinforcing its leadership in pharmaceutical logistics and positioning itself for future e-commerce challenges.