Ypê embarked on a major automation project with Joloda Hydraroll to transform logistics operations at its newly acquired greenfield site in São Paulo, improving the company’s quality, safety and environmental impact.

Founded more than 75 years ago, Ypê is one of Brazil’s best-known FMCG companies, specialising in the production of household cleaning products. In 2018, it partnered with system integration company E80 to create a pioneering campus for its new production and warehouse facilities.

The Challenge

The campus aimed to improve company safety standards, increase operational efficiency and reduce the environmental impact of transporting products. Due to increasing volume and scale of its operations, Ypê was looking to evolve its facilities with strategic enhancements to address:

• Human Error: Labour-intensive tasks are often tedious and repetitive, making them prone to human error. This can result in bottlenecks and safety hazards.
• Demand on Labour: Scaling operations to meet ambitious growth targets required significant focus on workforce development and retention at a time of rising labour costs.
• Health and Safety Risks: Forklift-heavy operations in busy areas pose safety risks and potential accidents.
• CO₂ Emissions: Frequent forklift use contributes to CO₂. With Brazil targeting a 67% emissions reduction by 2035, Ypê wanted to lead by example through greener logistics

The Solution

Ypê partnered with Joloda Hydraroll, a world leader in loading solutions, to assist with the optimisation of the loading process at the new facilities.

Given the volume of goods and the distance between the production facility and warehouse, a Slipchain Automated Trailer Loading System was implemented to limit manual handling, reducing risks in the workplace and improving efficiency.

The solution consisted of six loading docks in Ypê’s facilities: three at its warehouse, and three at its production plant. Furthermore, six slipchain trailer systems were installed to shuttle goods between the sites.

The Joloda Hydraroll Slipchain Loading Docks can communicate with the facility’s inventory management system to determine the size and weight of an item to be loaded. This means that the loading system can determine which pallets should be loaded onto which trailer for maximum efficiency in a process called sequencing.

Each loading dock also features a series of safety features to prevent incidents from occurring, including side barriers that act as physical barricades to prevent anyone or any piece of equipment from entering the loading dock’s perimeter.

Furthermore, sensors and warning signs were installed to let workers in the area know when the system was in operation.

In 2025, a fleet of self-driving Mercedes-Benz vehicles equipped with the slipchain systems was commissioned to shuttle trailers from the factory to the warehouse. These will enable around-the-clock operation between the production and warehousing facilities on the site, and further improve production capability.

Watch the solution in action, here.

Benefits

The implementation of automation has had numerous benefits for Ypê, including:

• Faster Loading: Trailer loading now takes just two minutes – a decrease in overall trailer turnaround time of around 28 minutes.
• Space Optimisation: The Joloda Hydraroll automated loading system has helped Ypê optimise storage space in both its production and warehouse facilities. Each system replaces three conventional docks and seamlessly integrates into existing production processes, eliminating the need for separate operations.
• Futureproofing: The automated loading system’s scalable nature ensures Ypê can expand effortlessly to meet increased demands and requirements.
• Sustainability: By reducing machinery, fleets of trucks, trailers, and forklifts, Ypê has reduced its CO2 emissions in keeping with global COP legislations, reinforcing its 75-year commitment to environmental responsibility.
• Safety Enhancements: Removing forklifts and adding smart safety systems has significantly reduced the risk of workplace accidents, ensuring a safer environment for employees.
• Reduced Product Damage: Automated loading systems eliminate product damage during pallet manoeuvring, ensuring stock moves seamlessly from the loading bay into the trailer without mishap.
• Automated Handling: The solution reduced labour-intensive operations, accompanied by professional upskilling, talent reallocation, and a shift toward higher-value activities.

Francisco Silva, Executive Manager for Excellence and Innovation at Ypê, commented: “I am delighted to express our satisfaction with the collaboration with Joloda Hydraroll. This partnership has truly exceeded our expectations, enabling us to streamline our logistics operations and enhance overall efficiency.

“The innovative solution provided by Joloda Hydraroll has not only optimised our processes but has also contributed to maintaining a safe and sustainable working environment. This project reinforces our culture of innovation, a value we have prided ourselves on since the company was founded in 1950. We look forward to continued success and future collaborations with Joloda Hydraroll.”

Conclusion

By embracing automated loading technology, Ypê has maintained its sustainable, innovative success in Brazil’s FMCG market, successfully addressing modern logistics challenges and positioning itself for future growth and sustainability goals.