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Materials Handling

Why Materials Handling Is Becoming a Bigger Issue Across Africa

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Warehouse worker using a pallet jack to transport packages
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Walk into almost any busy warehouse in Africa and you will see the same problem playing out.

A forklift is waiting for stock that has not been received properly. Pallets are stacked in the wrong place. Drivers are queuing outside loading bays. Someone is looking for a specific product that should have been dispatched two hours ago. Meanwhile, the sales team is asking why the customer has not received their order.

Most of the time, the problem is not that the warehouse does not have enough space. It is that goods are not moving through the space properly.

That is why materials handling is becoming a much bigger issue across Africa.

For years, many businesses treated warehousing as a back-end function. Goods came in, goods were stored, and eventually goods went out. But as retail networks expand, more products move across borders, and e-commerce grows, warehouses are under pressure to work faster and more accurately.

The forklift, pallet jack, racking system and loading bay have become far more important than they used to be.

The warehouse is no longer just a storage space

In Johannesburg, Nairobi, Lagos, Accra and Dar es Salaam, warehouses are becoming busier and more complex.

A business may receive imported stock through a port, move it into a warehouse, distribute it across several regions and then deliver smaller orders to retailers or customers. Every delay in the warehouse adds cost.

Take a food distributor as an example. A shipment arrives at the port and is transported to a warehouse outside Johannesburg. If the receiving team does not process it quickly, the stock sits on the floor. If the pallets are not correctly labelled, they may end up in the wrong storage area. If the picking team cannot find the stock when an order comes through, the truck leaves late.

That delay then affects the retailer, the shelf availability and eventually the customer.

It is easy to blame transport when deliveries are late. But in many cases, the delay started inside the warehouse.

Forklifts are still doing the heavy lifting

Despite all the talk about automation, most African warehouses still rely heavily on forklifts and people.

That is not necessarily a problem. A well-run warehouse with the right equipment can be highly efficient. The issue comes when companies use the wrong equipment for the job.

A small electric forklift may work perfectly in a clean indoor warehouse handling packaged goods. Put that same forklift into a rough outdoor yard with uneven surfaces, heavy loads and long operating hours, and it may struggle.

The same applies in reverse. A diesel forklift may be ideal for loading trucks in an outdoor building materials yard, but it is not always the best choice for a food or pharmaceutical warehouse where emissions and indoor air quality matter.

The equipment needs to fit the operation.

Many businesses make buying decisions based only on price. They look at the cost of the machine, but not the cost of downtime, repairs, fuel, battery charging, tyres, operator comfort or lost productivity.

The cheapest forklift is not always the cheapest option over three years.

A bad layout creates unnecessary work

One of the biggest problems in warehouses is poor layout.

You will often find fast-moving products stored at the back of the warehouse while slow-moving stock sits close to the dispatch area. Forklift operators spend large parts of the day driving from one end of the warehouse to the other. Pickers walk long distances. Trucks wait at loading bays because stock is not ready.

This is not always because people are working slowly. It is because the warehouse has been set up badly.

A simple example is a distributor that supplies supermarkets. The products that leave every day should be close to the dispatch area. Seasonal products or slow-moving stock can be stored further away. That sounds obvious, but many warehouses grow over time without anyone stepping back and redesigning the flow.

The result is that staff work harder than they need to.

In some cases, a better layout can improve productivity without buying a single new forklift or expanding the building.

Safety becomes harder as warehouses get busier

As warehouse activity increases, safety becomes more important.

Forklifts and pedestrians often operate in the same space. Trucks reverse into loading bays. Pallets are stored high in racking. Batteries are charged in corners of the warehouse. It only takes one mistake for someone to get hurt or for stock to be damaged.

The problem is that safety is often only taken seriously after an incident.

A forklift driver may be experienced, but that does not help if pedestrians are walking through blind corners. A warehouse may have good racking, but that does not help if pallets are overloaded or damaged. A loading bay may be busy, but that does not mean trucks should be allowed to move without clear procedures.

Basic controls make a difference: marked walkways, speed limits, proper lighting, daily forklift checks, racking inspections and regular operator training.

These are not glamorous changes, but they are the ones that prevent accidents and keep operations moving.

Technology is helping, but it does not need to be complicated

When people hear “warehouse technology”, they often think about robots and fully automated fulfilment centres.

That is not the reality for most businesses in Africa.

For many operators, the most useful technology is basic. Barcode scanners. Warehouse management systems. Digital stock counts. Simple dashboards. Better order tracking.

A warehouse does not need robots to become more efficient. It needs to know what stock it has, where it is stored and what needs to move next.

For example, a spare parts distributor may lose time because staff rely on paper records and memory to find stock. A basic barcode system can reduce errors and make it easier to locate parts quickly.

A retailer may struggle with stock discrepancies because goods are not scanned properly when they arrive. A simple receiving process with handheld devices can improve accuracy almost immediately.

Technology should solve a problem. It should not be bought because it sounds impressive in a presentation.

Africa’s logistics challenges make materials handling more important

Across Africa, supply chains already face challenges around transport costs, border delays, infrastructure constraints and inconsistent delivery times.

That means warehouses need to be more efficient, not less.

If stock takes longer to arrive because of a border delay or port congestion, the warehouse needs to manage available stock carefully. If transport is expensive, companies cannot afford to send half-empty trucks or make repeated deliveries because orders were picked incorrectly.

Materials handling sits right in the middle of this.

It affects how quickly goods can be received, how accurately stock can be stored, how efficiently orders can be picked and how reliably trucks can leave the warehouse.

For businesses operating across borders, this becomes even more important. A delay in a warehouse in Gauteng can affect a customer in Botswana, Zimbabwe, Mozambique or Namibia.

The businesses that get it right will move faster

The companies that will perform best are not necessarily the ones with the biggest warehouses or the newest equipment.

They will be the businesses that understand their own operation.

They will know which products move fastest. They will maintain their equipment. They will train their operators. They will design warehouses around flow, not just storage. They will use technology where it makes sense. And they will treat materials handling as part of customer service, not just a warehouse issue.

Because when goods move properly inside the warehouse, everything else becomes easier.

Trucks leave on time. Customers get their orders. Stock levels are more accurate. Staff spend less time fixing mistakes. And the business has a better chance of competing in a market where speed and reliability matter more every year.

Across Africa, the warehouse floor is becoming a place where supply chain performance is won or lost.

And in many cases, it comes down to something simple: how well goods are handled between arrival and dispatch.

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Management

AGOA is Back – But Can Africa Manufacture Its Way Into the Opportunity?

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A South African and US flag sitting on a desk with toy freight vehicles transporting goods. In the centre, lies two shipping containers painted with a South African and US flag with letters on top spelling AGOA.

We all know that global trade is becoming increasingly important. Economies are navigating challenges on multiple fronts, businesses are under pressure to remain competitive, and every opportunity to grow, invest and create new markets must be seized to lead to success.

But what if some of those opportunities are already within reach, and we simply aren’t making the most of them?

For Africa, one such opportunity is the African Growth and Opportunity Act.

AGOA is a U.S. trade programme established in 2000 to strengthen economic and trade relationships with eligible countries in Sub-Saharan Africa. It provides duty-free access to the U.S. market for more than 1,800 qualifying products, spanning a wide range of manufactured and value-added goods, including automotive components, textiles and apparel, agricultural and processed food products, chemicals, plastics, metals and other industrial products.

Following President Donald Trump’s announcement and the subsequent extension of AGOA through 31 December 2028, South African manufacturers have been given additional time and certainty to pursue opportunities in one of the world’s largest markets.

But access to a market is only part of the equation.

The real question is: are we equipped to take advantage of it?

Because securing an opportunity to supply an international customer is one thing. Having the machinery, skills, capacity and processes to fulfil that opportunity – consistently, competitively and at the required standard – is another.

For KNUTH Machine Tools, however, the significance of AGOA extends far beyond the trade agreement itself.

Does the African industry have the production capacity, technology and skills required to turn market access into manufactured exports?

“We often talk about market access as though it is the finish line. It isn’t. It is the starting point. If African manufacturers are going to compete for more international business, we need to build the production capacity and capabilities that allow us to compete -and deliver – at an international level,” says James Fourie, Technical Sales Team Lead, KNUTH SA.

For manufacturers across sectors such as automotive, mining, engineering and energy, increased export opportunities could mean greater demand, making it essential to optimise operations, improve productivity and strengthen production capacity.

From Market Access to Manufacturing Capacity

The renewed focus on AGOA comes at a time when manufacturers globally are under pressure to produce more efficiently while controlling costs and maintaining consistent quality.

For African manufacturers, the opportunity is therefore not simply about exporting more. It is about being equipped to manufacture more competitively.

There are plenty of ways manufacturers can improve how competitively they operate. It can start with something as simple as identifying production bottlenecks, reducing downtime or getting more out of existing equipment. For others, it may mean improving production planning, reviewing tooling and processes, upgrading ageing machinery, introducing CNC technology or investing in automation.

Just as importantly, manufacturers need the right skills to make the most of these improvements and ensure that technology translates into real gains on the shop floor.

“Manufacturing competitiveness starts long before a product reaches the shipping container,” says Ruan Cowley, Managing Director of KNUTH SA. “It starts with the equipment, the people operating it and the processes behind it. If AGOA creates additional demand, manufacturers need to be ready to respond to that demand, and that requires investment in production capability.”

This is particularly relevant for businesses that may currently be operating with limited capacity or processes that are already under pressure.

A manufacturer receiving an opportunity to supply a larger international customer cannot necessarily scale simply by adding another order to the production schedule. Increased volumes can expose operational inefficiencies.

The result is that market access can quickly become a manufacturing-capacity challenge.

The Machinery Question

For more than 100 years, KNUTH Machine Tools has been part of the global manufacturing industry, working alongside manufacturers as production methods, technologies and market demands have evolved.

That experience has shown that improving manufacturing competitiveness is rarely about one machine or one investment. It is about understanding the operation as a whole.

For machine shops and component manufacturers, technology can play an important role in that process. Modern CNC machinery, for example, can improve consistency, reduce manual intervention and support the production of more complex components. But the right technology depends on the needs of the individual operation.

“Buying a machine is not the same as improving a manufacturing operation,” says Fourie. “You first need to understand where the constraints are. It could be capacity, workflow, skills, tooling, programming or simply the way a process is being managed. Once you understand that, you can make more informed decisions about where technology can add real value.”

That broader approach becomes increasingly important as manufacturers look to compete for international business.

Ultimately, the goal is not simply to have more technology on the factory floor. It is to build more capable, efficient and competitive manufacturing operations.

“International competitiveness isn’t built overnight,” says Cowley. “It requires manufacturers to make decisions today that improve their ability to compete tomorrow. That includes machinery, skills, service, maintenance and the ability to keep production running.”

A Window – Not a Guarantee

AGOA’s current authorisation runs through the end of 2028, while the United States has also begun a process to consider how the programme could be modernised.

That means manufacturers should view the current environment as an opportunity to assess their readiness rather than simply waiting for export demand to appear.

AGOA is also not the only preferential trade opportunity available. Through agreements and arrangements such as SACU, SADC, the African Continental Free Trade Area (AfCFTA), the SADC–EU Economic Partnership Agreement, the SACUM–UK Economic Partnership Agreement, SACU–EFTA and SACU–MERCOSUR, South African businesses have access to a range of regional and international markets under preferential trading conditions.

The markets are there. The opportunity is there. The question is whether African manufacturing is ready to make the most of it.

For KNUTH, that means encouraging manufacturers to consider a more fundamental question: If a new international opportunity came across the desk tomorrow, would the factory be ready to produce it?

The market may open the door. Manufacturing capability determines whether you can walk through it.

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Logistics

SAFLA Launches Gauteng Region With Eric Pillay Appointed As Chairperson

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Group photo of: Arend du Preez: Vice Chair of SAFLA, Gavin Kelly: CEO of the Road Freight Association, Jonathan McDonald: Vice Chair of SAFLA’s and Freek van Rooyen - Partner: Shipping & Logistics at Shepstone & Wylie.

The South African Freight and Logistics Association (SAFLA) has launched its Gauteng region, appointing Eric Pillay as regional chairperson and placing stakeholder engagement, border delays and port bottlenecks at the centre of its agenda.

Pillay, owner of Pro-Active Shipping & Freight Solutions, will lead the region’s efforts to strengthen industry representation and improve engagement with the organisations that influence cargo movement. “We work closely with SAFLA nationally to ensure that our issues are addressed,” Pillay stated, outlining how the Gauteng chapter will connect regional concerns with SAFLA’s countrywide advocacy and engagement.

The official launch breakfast at the Johannesburg Country Club in Woodmead, brought together freight and logistics colleagues and key stakeholders to mark the establishment of a regional platform supported by SAFLA’s national structures.

A Collective Voice for Gauteng

Pillay said the chapter responds to clearing and forwarding companies’ need for a collective voice in their dealings with organisations such as the Border Management Authority and other state-owned enterprises and shipping lines. Its first-year priorities centre on improving stakeholder relationships to boost trade and support regional growth, with border and port delays receiving immediate attention.

Pillay’s longer-term vision focuses on stronger partnerships and efficient cargo movement across Gauteng’s supply chains. “Transport is key to keeping the economy going and I would like to see increased cargo volumes moving efficiently, freely and safely.”

SAFLA Gauteng welcomes companies operating in clearing, forwarding and transport in Gauteng. Smaller and emerging operators can use its platform to raise concerns and access support in navigating industry challenges.

Regional Action Supporting National Reform

SAFLA chair Arend du Preez highlighted the association’s commitment to strengthening regional representation within a unified national framework. “By strengthening our regional representation, we ensure that local concerns are heard, local expertise is utilised, and local solutions can be developed while still benefiting from national support and coordination,” du Preez explained.

He emphasised constructive engagement between industry participants to identify the causes of disruption and resolve operational pressure points. “At the end of the day, our objective remains simple,” he said. “Cargo must move.”

Economic Regulation, Fair Access and Transparent Pricing Highlighted

Guest speaker Ian Bird, Transport & Logistics Focal Area Lead at Business for South Africa, addressed the business-government partnership and progress on logistics reforms, placing the regional launch within the broader effort to improve South Africa’s freight system.

Bird’s presentation highlighted the importance of effective economic regulation, fair access and transparent pricing in encouraging investment. “Effective regulation builds confidence and unlocks investment,” Bird highlighted in his presentation.

Ian Bird: Transport & Logistics Focal Area Lead – Business for South Africa – presenting at an event.

Ian Bird: Transport & Logistics Focal Area Lead – Business for South Africa

He also stressed that to deliver the freight volumes so urgently needed by the economy will require both improving the rail network for Transnet and private Train Operating Companies, as well as implementing a comprehensive program of structural reform.  The growth in rail volumes will be driven by general freight, which by it’s very nature requires more complex supply chains being developed, operated and managed.

For SAFLA Gauteng, these national priorities reinforce the value of sustained regional engagement with supply chain stakeholders and coordinated escalation of members’ concerns.

SAFLA’s Gauteng chapter aims to help remove bottlenecks, reduce the costs associated with delayed cargo and support trade competitiveness through practical collaboration. Members can also raise local operational issues through SAFLA’s national structures.

Commenting on the launch, Road Freight Association (RFA) CEO Gavin Kelly said the RFA’s MoU with SAFLA means a “stronger, more coordinated industry voice,” while Warwick Lord, chairperson of the Multimodal Inland Port Association (MIPA), added that MIPA “looks forward to working with the association for the benefit of its members and the industry.” Paul Matthew, CEO of the African Meat Importers and Exporters Association added: “Importers and exporters depend on efficient, well-represented freight forwarders. We are proud to partner with SAFLA”.

Headshot of Warwick Lord: Chairperson – Multimodal Inland Port Association (MIPA)

Warwick Lord: Chairperson – Multimodal Inland Port Association (MIPA)

“It means a great deal to me to be part of SAFLA,” continued Pillay. “The industry has been longing for a voice to air their issues and now we have it.”

Portrait of Eric Pillay: Owner - Pro-Active Shipping & Freight Solutions

Eric Pillay: Owner – Pro-Active Shipping & Freight Solutions

Portrait of Paul Matthew: CEO – African Meat Importers and Exporters Association

Paul Matthew: CEO – African Meat Importers and Exporters Association

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Management

Newlyn Advances Gqeberha Logistics Park with Second Warehouse Planned

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Focused shot of a warehouse interior with a forklift.

Newlyn Group is moving ahead with the development of its Newlyn Logistics Park in Gqeberha, with the first 10,000m² warehouse nearing completion and construction of a second facility scheduled to begin in October 2026.

Located along Cape Road (R102), around 5km from the N2 and approximately 20 minutes from the Port of Gqeberha, the development is designed to accommodate logistics, distribution and light manufacturing businesses. The wider logistics park covers approximately 150,000m², with additional warehouse phases planned as demand develops.

The first phase includes a 10,000m² warehouse, a matching 10,000m² yard and between 200m² and 300m² of office and ancillary space. Completion is expected by December 2026. The next phase will add another warehouse of the same size, supported by a dedicated yard.

Warehouse Design Focuses On Operational Efficiency

Rather than focusing solely on warehouse size, Newlyn has incorporated features intended to support the practical requirements of storage, handling and distribution operations.

The buildings have a 24m by 24m column grid to provide open operating space, alongside a clear internal height of 10.5m beneath the structural trusses. This allows for racking of approximately 9m to 10m, or around seven levels, using conventional materials-handling equipment.

The warehouse floors are designed to support distributed loads of 10 to 12 tonnes, with joints positioned to account for racking layouts and the loads placed on rack legs. These considerations can help reduce the need for costly modifications when tenants install their storage systems.

Outside, heavy-duty paved yards are designed to withstand truck and reach-stacker movements. The development also incorporates reinforced concrete in high-turning and high-wear areas to accommodate the demands of regular vehicle movements.

These specifications are intended to help businesses configure their facilities around their operational needs, from goods storage to loading and dispatch.

Infrastructure Designed for Long-Term Use

The development also incorporates features intended to address energy use, building maintenance and Gqeberha’s coastal conditions.

Steelwork has a 15-year anti-corrosion specification, while the roof system is designed without penetrations. The structures are also engineered to accommodate rooftop solar panels, allowing tenants to add photovoltaic capacity without requiring retrospective structural strengthening.

Translucent roof sheeting allows natural light into the warehouse during the day, while ventilation systems support fresh-air circulation and smoke extraction. LED lighting can also be paired with motion or timing sensors to limit unnecessary energy use.

Fire protection is another key consideration. The logistics park will use a shared dual-tank, dual-pump firefighting water system designed to support firefighting in two buildings simultaneously for up to two hours. Warehouse sprinkler systems, early-warning smoke detection and smoke curtains form part of the wider fire-safety provisions.

Utility infrastructure includes individual electricity and water meters, backup water storage and a borehole alongside the municipal supply. Stormwater systems have also been designed to account for the site’s floodplain conditions.

Security will combine perimeter fencing and AI-enabled camera monitoring with a central control room. Individual tenants will be able to establish additional security measures around their own operations.

Further Phases to Respond to Demand

Newlyn has approved plans for additional warehouse options of 12,000m², 7,000m² and 3,000m² as the logistics park expands. This gives the developer scope to respond to different occupier requirements rather than committing to a single warehouse size across the entire site.

According to Viresh Persad, Newlyn Group’s chief development officer, the aim is to incorporate practical operational requirements into the initial building design while retaining flexibility for different tenants.

The development adds to the warehousing infrastructure available in Gqeberha, with its location providing access to the N2 and the Port of Gqeberha. For logistics operators, the combination of transport links, yard capacity and adaptable warehouse space will be central to determining how well the facility meets their distribution and storage needs.

Source: Newlyn Group, via Catchwords Newsroom.

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