delivered a new system that would significantly speed up deliveries and reduce shrinkage. Implementation has already begun and is scheduled for completion in June this year when a state-of-the-art 2400sq/m warehouse in Hammarsdale becomes fully operational.

Botha explained that the company had examined existing packaging and noted its shortcomings, inspected material handling methods and analysed quantities delivered to customers over two years to determine whether there were any commonalities. Project managers were given an open brief to improve both the security and protection of products, as well as decrease the number of errors and speed up delivery times.

“It’s about getting the right product to the customer at the right time. This is about adding value to our service. This innovation means that we’ll save money and be able to pass this on to customers at a time when all are feeling the pinch due to rising input costs, rocketing fuel prices and a slowing economy.”

When deliveries were analysed, it was found that 75 percent of customers ordered product in similar amounts or multiples.  Thanks to these commonalities, Glodina was able to standardise case lots. Botha expects this to suit up to 98 percent of customers when the new system is implemented.

When it came to improving packaging, Botha said it was impossible to find a durable alternative that remained environmentally friendly. So, Glodina decided to stick with cardboard. The only compromise has been to shrink wrap the now smaller boxes and line the insides with plastic to keep product clean and prevent the boxes from tearing. Because it is now extremely difficult to open boxes, shrinkage through theft and damage to the towels will be minimised. 

Wastage has also been reduced because boxes will not have to be reopened to check or repacked to suit individual customers. Up until now, up to 50 percent of the original cartons were thrown away. Using fewer boxes not only spares the environment, but also saves money.

Glodina’s smaller boxes have been specially designed to be more densely packed resulting in them being far stronger. With no dead space, boxes do not collapse. They are also easier to handle and deliveries can be optimised. (In other words, more boxes are dispatched on each truck so fewer trips to customers are needed). Boxes are also not as heavy and far easier to handle, which benefits both Glodina and its customers. 

On the warehouse floor, Glodina has already implemented two innovative systems. A sophisticated barcode labelling system not only speeds up product selection within the warehouse, but also contains critical product information such as colour and size to eliminate errors.

Boxes can now be selected and despatched by weight. According to Botha, every box will also be sequentially numbered. Unfortunately, even though dyes are tested against previous batches of towels, they do alter slightly. The new system will put paid to delivering ‘mismatched’ towels produced at different times.

State-of-the-art order picker machines have been introduced to improve efficiency. Once the new warehouse is operational, Glodina will be able to stack product by customer, which will further reduce material handling. Gone are the days of confusion thanks to mixed pallets of stock.

All in all, says Botha, customers will no longer have to tear open cartons to examine and count the numbers of towels delivered. It will simply be a case of taking them out of the box and merchandising them on the shelf.

Glodina will also continue to benefit from a more efficient and accurate stock control and quicker distribution. “While we’ve been streamlining, we’ve also picked up and begun improving a host of other things within our factory and delivery process. These were actually things we weren’t even looking for and will add further value to our product offering!”