Connect with us

Materials Handling

Why Materials Handling Is Becoming a Bigger Issue Across Africa

Published

on

Warehouse worker using a pallet jack to transport packages
Admin

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.

Continue Reading

Materials Handling

South Africa’s E-Commerce Boom is Hiding a Profit Crisis

Published

on

Landscape image of a South African flag with flow charts over an e-commerce shop

South Africa’s e-commerce sector is booming. The market is on track to surpass R130 billion in turnover this year. Local online sales are growing at roughly 20% and the sector handles over 100 million shipments annually. According to World Wide Worx, online shopping now represents 8% to 10% of total national retail – expanding at nearly ten times the rate of traditional brick-and-mortar stores.

But the uncomfortable truth is that while revenue is rising, profit margins are shrinking.

The problem isn’t marketing

When profits come under pressure, most merchants reach for the same playbook. They spend more on ads, push harder on sales, or negotiate lower product costs, rarely looking in the right place. The real profit drain doesn’t happen in marketing. It happens silently in fulfilment and last mile delivery. Margin loss is a death by a thousand cuts, from small, hidden inefficiencies spread across delivery networks, fuel surcharges, poor courier choices, and unexamined invoices.

If you want to protect your margins, you need to stop these seven main profit leaks.

1.      Unchecked Last-Mile Costs

Globally, last-mile delivery accounts for up to 53% of total logistics costs, and South Africa is no exception. As customer expectations around free or discounted shipping rise, unmanaged delivery fees quickly erode profit per order. Smart merchants constantly benchmark courier rates and avoid relying on a single provider.

By testing multiple options based on price, location and delivery requirements, you can protect margins without sacrificing speed and reliability. Or choose a platform that offers multiple courier partners.

2.      Unpredictable Fuel Surcharges

Fuel is one of the largest cost variables in local transport. Couriers adjust their fuel levies monthly, making shipping expenses unpredictable. If you only look at your base shipping rates without tracking fluctuating landed costs, your margins will take a hit.

Shipping platforms that provide transparent, up-to-date rates and factor fuel surcharges into the total costs give you a clearer picture of actual spending. This can help you spot the most cost-effective options.

3.      Poor Courier Allocation

No single courier performs equally across the entire country. A provider with great coverage and pricing in Cape Town might deliver poor service or higher rates in Durban or Johannesburg. Assigning orders based on rigid rules leads to higher costs and slower delivery times.

Solutions to this issue do exist, and a good place to start is by matching the courier you’re going with to your specific delivery zone based on real-time cost and success rates.

Shipping solutions can enable your business to connect with multiple courier partners. These platforms support teams in dynamically selecting the best carrier for each delivery area. This is based on current rates, coverage, and delivery performance data. The right partnership should lead to lower shipping costs while improving delivery reliability across provinces.

4.      The Cost of Failed Deliveries

Every failed delivery attempt hits your bottom line. Every return-to-origin attempt results in extra fuel, customer support time, and re-routing. Simple fixes like automated address validation and proactive delivery tracking notifications can significantly reduce these unnecessary attempts, keeping customers informed at every step.

5.      Reverse Logistics Escalation

Returns are a double penalty. Processing a return creates a second fulfilment journey, with extra transport costs, inventory hold-ups, and double handling. Track which products and locations generate the most returns. Understanding your return hotspots helps you spot delivery exceptions early and prevent items from heading back unnecessarily.

6.      Unaudited Billing Discrepancies

Small invoice errors quickly multiply when you’re moving thousands of monthly dispatches. Volumetric weight adjustments, incorrect service charges, and system mismatches are just some of the typical suspects. Without regular invoice audits and automated reconciliation, you are likely overpaying. The right tools match courier invoices against actual shipment details. This assists in identifying billing discrepancies and overcharges before they accumulate across thousands of orders.

7.      Operating in the Dark

You cannot fix what you do not measure. Most e-commerce teams closely track sales, web traffic, and conversion rates, but few have clear visibility over their true fulfilment cost per order or individual courier performance.

Real time logistics dashboards are the only way to catch operational leaks early. They provide visibility and actionable insights from one place, giving you the data you need to make smarter decisions.

Moving Beyond Cheaper Rates

Protecting your margins is not simply about demanding cheaper shipping rates. It requires a shift toward intelligent, data-driven fulfilment.

By adopting multi-courier management strategies, dynamically routing packages based on regional performance, and automated invoice auditing, South African merchants can safeguard their bottom line. In a competitive market, sustainable growth belongs to the merchants who manage their operational details as tightly as their sales funnels.

The profit leaks are there. You just need to find them. 

Portrait shot of Angus LePine Williams, Head of Operations at Shiprazor

Written by: Angus LePine Williams, Head of Operations at Shiprazor

Continue Reading

Logistics

When Demand Changes, Supply Chains Need to Keep Up

Published

on

Close up of a shipping yard worker completing paper work on a clipboard

Not that long ago, supply chains relied heavily on forecasts. Businesses analysed previous sales, estimated future demand and planned months ahead. Inventory was ordered, transport was booked and warehouse space was allocated based on what companies expected customers to buy.

Forecasting is still an important part of supply chain planning, but business doesn’t always follow the plan.

Customer demand can change far more quickly than it once did. A product can suddenly become popular after receiving attention online, seasonal demand may arrive earlier than expected or economic conditions can change how consumers spend almost overnight. In those moments, businesses that stick rigidly to the original forecast often find themselves reacting too late.

The conversation is gradually shifting. Rather than asking, ‘Did we forecast correctly?’, more organisations are asking, ‘How quickly can we respond when demand changes?’

Forecasts Are the Starting Point, Not the Finish Line

Forecasts remain one of the most valuable planning tools in the supply chain. Manufacturers still need time to produce goods, procurement teams need to secure materials and transport providers need advance notice to plan capacity.

The difference is that forecasts are no longer treated as something that can’t be changed. They’re becoming working plans that evolve as new information comes in.

That flexibility is proving just as valuable as the forecast itself.

Listening to What the Supply Chain Is Telling You

Every customer order, inventory movement and delivery generates information. On its own, that data doesn’t say much. Over time, though, it begins to paint a picture of how demand is changing.

A product that starts selling faster than expected gives planners the opportunity to adjust purchasing before stock runs out. Equally, slower sales can signal that it’s time to rethink future orders before excess inventory starts filling valuable warehouse space.

It’s less about reacting to every fluctuation and more about recognising when a change is becoming a trend.

Responding Takes More Than Good Data

Knowing that demand has changed is only part of the challenge. The real test is whether the rest of the supply chain can respond.

If procurement can’t source materials quickly enough, warehouses don’t have available capacity or transport schedules can’t be adjusted, even the best demand information has limited value.

That’s why visibility has become so important. When procurement, warehousing, transport and inventory teams are working from the same picture, they’re able to make decisions with far greater confidence and far fewer surprises.

Adaptability Is Becoming a Competitive Advantage

No forecast will ever be perfect, and most supply chain professionals know that. The real advantage comes from recognising when reality begins to drift away from the original plan and having the flexibility to respond before customers feel the impact. Businesses will always need forecasts. They provide direction, support investment decisions and help supply chains prepare for what’s ahead. Increasingly, though, success depends just as much on what happens after the forecast is written as it does on the forecast itself.

Continue Reading

Logistics

Stress-test for Black Friday now

Published

on

Banner of a South African flag combined with a Black Friday countdown

By Sahil Affriya, Founder & CEO, Shiprazor

I find myself having the same conversations with business owners in late November – always too late to make a difference. They typically have three strong trading days as customers work through their wish lists. Then a public holiday comes and nothing moves, followed by a new week that opens with forty parcels sitting on a late collection and customers on WhatsApp politely asking where their orders are. You know that courtesy has a shelf life.

Most merchants treat that new week as something to survive, but working with them day-to-day has shown us that it is far more useful to use these long weekends as a dry run for the biggest shopping weekend of the year – Black Friday/Cyber Monday.

The upcoming Women’s Day long weekend provides an excellent opportunity to dry run the three pressures that define Black Friday: an order spike, a pause in collections, and a backlog clearing while new orders land. Get it wrong in August and you could lose a few customers; in November, you stand to lose the season.

This matters more each year as larger retailers keep shrinking the gap between order and doorstep, and shoppers expect everyone to match it. Services like Checkers Sixty60 have passed 100 million orders across close to 700 stores. The delivery speed shoppers expect from their grocery run has become the benchmark every other vendor is measured against. More people are placing more orders, and growing less patient with a poor delivery service.

Business owners have roughly ten weeks before an October system freeze locks things down. Here are four things you can do to stress test for Black Friday before it’s too late to make code changes.

1. The gap between purchase and waybill

Your first possible bottleneck sits just past checkout in the time between an order landing and you being able to create a waybill. Ideally, that gap is seconds. If it takes hours, or you are typing an address into a courier portal, you have found your first problem and higher order volumes will only worsen it.

Get ahead of this by tracking what stalls: failed connections, duplicate shipments, orders stuck on pending, anything needing a manual fix. On a well-integrated platform, that count sits near zero and the waybill follows the sale automatically, freeing your team to focus on the customer, not the admin.

2. What the customer sees after dispatch

Late parcels don’t automatically lose customers but silence can. A shopper who cannot see their order assumes the worst and messages you. Each assumption puts the success of your weekend and reputation at risk. Your focus should be on tracking exceptions, non-delivery reports (an NDR is logged when a courier cannot complete a delivery), return-to-origin rates, repeat attempts, and “where is my order” messages piling up.

Many failed deliveries are caused by a wrong or incomplete address, and each one comes with costs: a redelivery, the time cost of a support call, and sometimes the sale itself. Proactive tracking systems that keep customers up to date answer most of those questions before they are asked.

3. Courier performance on your own routes

Most merchants set their courier rules once and never look at them again, and many take advertised transit times at face value rather than as a claim to test. Testing these systems and asking critical questions of your courier partner is the key to getting ahead of any problems.

Testing lets you quantify the value you are getting from each courier and plan for contingencies. Relying on a single courier means your only backup plan is hope. The stress of managing multiple delivery providers, however, pulls your attention away from your customer. Platforms that give you the option to choose from multiple couriers enable stability even when systems are under pressure.

4. Every step that still needs a person

Question every manual process: courier allocation, waybill generation, address correction, customer notifications, status updates. When you are small, doing some of these by hand is manageable; for a business that is scaling, this quickly becomes unsustainable.

Note every point where someone had to step in to complete a routine task and treat each one as something to automate or rewrite. The right setup takes that work off your team entirely: a single integrated platform that turns a sale into a waybill, multi-courier routing that reroutes in seconds, and tracking that keeps customers informed before they need to ask.

Read the data the week after the holiday, fix your three biggest weaknesses by the end of September, and confirm the fixes hold before the freeze. Do that and the calm forty-order weekend and the frantic four-hundred-order one should feel the same to your team. Leave the diagnosis until Black Friday and you will learn the same lessons at a far higher price.

Sahil Affriya, Founder and CEO of  Shiprazor, attending an event in a suit

Sahil Affriya, Founder & CEO, Shiprazor

Continue Reading

ADVERTISEMENT

Random Image
Advertisement

Trending