PRL Tecnosoft’s solution for Linea Verde
Linea Verde, headquartered in Manerbio (Brescia), is one of Europe’s leading producers of fresh-cut salads (fourth range) and ready to eat fresh meals. With a production volume of around two million packs per day, supported by eight sites across Italy, Spain, France and Serbia, the company stands out as an example of integration between industrial capability, technological innovation and process automation.
Linea Verde oversees the entire supply chain, from field to table, with a focus on production efficiency, quality and food safety. In 2024, it achieved a turnover of €378 million and employs more than 1,600 people.
The Manerbio plant needed to automate twelve manual packaging lines operating under extremely complex conditions. Space was limited by a mezzanine with a maximum height of 220 centimetres, while the cold and humid environment represented an additional challenge. The real difficulty lay in handling 583 different products, weighing from 40 grams to 1 kilogram, to be packed into 25 different formats of plastic and cardboard trays. The customer required a single machine capable of managing all these formats, delivering 70 pieces per minute and integrating an output tray stacker.
PRL Tecnosoft developed an ultra compact case packing machine measuring 1500 x 4650 mm with a height of 2500 mm, engineered to make the most of every available centimetre. The core of the system comprises two delta robots guided by a sophisticated artificial vision system capable of recognising and precisely handling all 583 product types.
The distinctive feature is the customised gripper, fully developed by PRL Tecnosoft, capable of handling 90% of the formats. An alternative gripper, with reduced dimensions, was created to ensure rapid changeover. The stainless steel structure and purpose designed layout simplify cleaning and maintenance.
The 21 inch touchscreen interface allows intuitive operation through a multi recipe system, replicable across all twelve machines. Seven LED lights communicate operating status, while an automatic air blowing system keeps the lighting units clean. Accessibility is ensured by sliding doors that optimise the limited space.
The prototype was built in seven months, followed by eleven additional machines delivered between September and December 2025. Linea Verde now has twelve identical machines that handle the entire production range through a single technological platform, achieving the required productivity and ensuring maximum operational flexibility. A partnership that has turned spatial constraints into an opportunity for innovation.
