The LATI Production Process

Technology, People, Continuous Transformation.

In the heart of the Varese province, in Gornate Olona, lies LATI's most advanced factory: a production hub that represents the benchmark for the company's investments in digitalization, automation, and process innovation. Here, every production phase has been designed to integrate intelligent technological solutions with people's experience and skills, in an industrial model that focuses on traceability, safety, precision, and sustainability.

The result is an interconnected production chain, where facilities, management systems, and operators work in synergy to ensure quality and reliability, every day.
Raw Materials Warehouse

1

Raw Materials Warehouse

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Preparation & Weighing

2

Preparation & Weighing

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Mixing

3

Mixing

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Extrusion

4

Extrusion

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Drying & Packaging

5

Drying & Packaging

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Logistics & Shipping

6

Logistics & Shipping

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Raw Materials Warehouse

Structure, Technology, Safety.

The raw materials warehouse represents the first strategic hub of the supply chain:

  • Capacity: 5100 rackable pallets, on a surface of 70 meters in length, 55 in width, and 12 in internal height.
  • Structure: 12 aisles with 24 6-level racks.
  • Logistics: covered loading bay of 900 m² and 4 tilting unloading ramps.
  • Technology: trilateral forklifts with semi-automatic navigation system, guided by wire guidance and transponders.
  • Safety: structure compliant with seismic regulations, ESFR K360 sprinkler system for fire protection.
  • Versatility: manages rackable load units such as boxes, bags, octa, big bags, tetra.
Raw materials warehouse - LATI Gornate Olona

Advantages:

Digital Traceability of Material Positions.

Integration with LATI's SAP Management System.

Reduction of Paper Documentation and Operational Errors.

Increased Safety Thanks to the PPS System for Personnel Protection.

Preparation & Weighing

Advanced Technology and Precision in the Service of Safety.

Two systems work in synergy to perform automatic weighing and ensure recipe quality:

  • TRS: 65 silos and 4 BigBag stations for automatic component weighing.
  • MagRob: racking for box storage, automatic delivery system, and rotating carousel with 6 weighing stations.
Compound preparation and weighing - LATI

Operational benefits:

Complete Traceability of the Component Batch.

Real-time Stock Updates.

Reduction of Manual Activities and Improved Ergonomics.

Chemical safety: the new machinery for additives and colorants (introduced in 2022) prevents dust dispersion and limits spills.

Supporting digital technologies:

Direct Connection with SAP through MII/IOT System.

Remote Diagnostics and Interfaces that Simplify Human-Machine Interaction.

Batch Tracking, Consumption Updates, and Real-Time Order Progress.

Mixing

Control, Safety, Consistency of the Pre-Mix.

The components are mixed to obtain a homogeneous pre-mix, ready for the extrusion lines:

  • 4 horizontal slow mixers of 4000 L (20-30 minutes per batch).
  • 2 cup turbo mixers of 600-800 L (5-6 minutes per batch).
  • Weighing stations connected to 12 silos, packaging change stations, and manual loading of additives and fillers.
  • Water washing system.
Mixer at Gornate Olona

Advantages:

Formula Homogeneity.

Safety in Manual Activities.

Traceability and Continuous Monitoring Thanks to Integration with SAP via MII/IOT.

Extrusion

Flexibility, Control, Performance.

The extrusion lines represent the heart of the transformation:

  • 9 extrusion lines, with co-rotating interpenetrating twin-screw extruders.
  • Diameters from 70 mm to 92 mm, power from 242 to 627 kW.
  • 4 to 9 gravimetric feeders per line.
  • Separate systems for fume, vapor, and dust extraction.
  • Integrated water treatment.
Plastic compound extrusion - LATI Gornate Olona.jpg; Thermoplastic Material Granules - LATI Gornate

Technological strengths:

Customized Set-Up for Product Type.

Maximum Flexibility for Production Needs and Timeline Compliance.

Real-time Monitoring of Process Parameters.

Compliance with all HSE, ATEX, and CE Marking Requirements.

Digital control:

Interfaces connected to SAP (via MII/IOT) for order details, component traceability, and digitalization of set-up instructions.

Time Tracking and Automatic Consumption Reporting.

Drying & Packaging

Final Precision for a Product Ready to Go.

After extrusion, the material goes through a crucial phase that ensures its final quality and logistical efficiency: drying and packaging.

Drying Area

  • 4 vacuum ovens of 12,000 liters each allow for deep and controlled drying, ensuring the homogeneity and stability of the finished product.

Packaging Area
A diverse plant equipment allows maximum flexibility in packaging:

  • 2 lines for 15, 20, and 25 kg bags.
  • 2 lines for boxes and Big Bags.
  • 1 line dedicated to direct packaging in tanker trucks.

Operational benefits:

Homogeneous Drying for Consistent Batch Quality.

High Precision in Weighing each Individual Package.

Accurate Labeling, to Ensure Complete Identification and Traceability of Packages.

Digital integration
This phase is also fully integrated with the LATI SAP management system, thanks to the connection via MII/IOT platform. This allows:

Real-time Monitoring and Tracking of each Package

Automatic Synchronization of Production and Packaging Data

Improved Logistics Efficiency and Quality Control

Logistics & Shipping

Precision Even in the Final Phase.

The management of finished products is entrusted to the partner Magazzino Innocenti, just 5 km from the highway, in the eastern area of Milan:

  • 8000 pallet positions, 20 aisles, 6-level racking.
  • Radio frequency for all warehouse activities.
  • Direct rail connection for train shipments.
  • Daily shuttles with dedicated shuttles from LATI to the logistics partner.
Logistics & shipping - LATI

Benefits:

Optimization of Customer Service and Order Management through SAP.

Maximum Traceability of Moved Units (LU).

Standardization of Pallets.

LATI Adopts the Lean Method to Improve Production

Technology and people, together.

We are implementing the Lean method to optimize our production processes, reduce waste, and improve efficiency.
Our goal is to create a leaner work environment, where every phase of production is continuously monitored and improved.
To achieve this, we have introduced systems to measure performance and constantly analyze results, involving all work groups in process management and goal achievement. We also use visual tools to make workflows clear to everyone, allowing for quick identification of any inefficiencies.
Every day, teams meet to review activities, share ideas for improvement, and define concrete actions to optimize processing times. To ensure order and safety, we are applying cleaning and organization practices that involve every department, while we are also reducing machine downtime to speed up material changes. These changes allow us to respond more quickly to market needs, while always maintaining high quality standards.

At LATI, innovation is our driving force: every day, we make production smarter, faster, and safer, to ensure an ever-better future.

News from the Heart of LATI Production

Our factory is constantly evolving.
Here we share updates on facilities, technologies, and projects that are transforming the way we produce: more efficiency, more safety, more value for people.
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Let's talk about it together

Want to know more about who we are, what we do, or how we can collaborate? LATI is ready to listen to you.

Contact us to learn more about our materials, to delve into our production process, or simply to start a conversation. Every relationship begins with a first exchange. The next one could be yours.

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