Barilla Automates Final Mile: Robots Now Load Trailers at Dock

Barilla has implemented an automated pallet-loading system at its largest pasta manufacturing facility in Pedrignano, Italy, marking a significant step in end-to-end warehouse automation. Rather than stopping automation at the dispatch area as most facilities do, the system extends laser-guided vehicles (LGVs) into the trailer itself, eliminating the need for manual forklift operators during loading. This innovation, developed by E80 Group and integrated with Rite-Hite loading-bay equipment, addresses safety concerns and improves operational control while adapting to existing infrastructure rather than requiring a facility redesign.

The Pedrignano facility has undergone substantial expansion since 2013, growing from 40,000 to 165,000 square meters, increasing its LGV fleet from 54 to over 100 vehicles, and adding 35 robotic devices across palletizing, labeling, and wrapping operations. The warehouse alone eliminated over 3,000 annual lorry journeys by reducing reliance on external storage, demonstrating how internal automation cascades into transport optimization. The new trailer-loading automation represents the logical next evolution: as warehouses become increasingly autonomous, the handover between internal systems and outbound vehicles becomes the next frontier.

For supply chain professionals, this development signals a structural shift in how dock operations will be organized. Equipment specifications like vehicle restraints, loading-bay layouts, and trailer compatibility will become critical requirements rather than afterthoughts. Organizations relying on Barilla or competing with similar facilities must prepare for operational changes, potentially including driver role redefinition and new carrier qualifications for facilities equipped with automated loading systems.