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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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Logistics

Stress-test for Black Friday now

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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

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Logistics

Why Regional Trade Isn’t as Simple as Crossing a Border

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Admin

On a map, regional trade looks straightforward. South Africa shares borders with six neighbouring countries, while the Southern African Development Community (SADC) connects businesses across a market of hundreds of millions of people. Moving goods across the region should, in theory, be one of the easiest ways for businesses to grow.

The reality is often far more complicated.

Getting a truck from Johannesburg to Gaborone or Lusaka involves much more than covering the distance. Border procedures, customs requirements, road infrastructure and transport delays all influence how quickly goods reach their destination. For many businesses, crossing a border remains one of the least predictable parts of the journey.

The Border Is Often Where Momentum Slows

A truck arriving at a border post isn’t necessarily close to completing its journey. Depending on the route, drivers can spend hours, and sometimes longer, waiting for documentation to be processed, inspections to be completed or traffic to clear.

Those delays don’t just affect delivery schedules. Vehicles remain out of service for longer, transport costs increase and businesses lose flexibility when responding to customer demand.

For companies managing time-sensitive goods or tightly planned delivery schedules, a delay at the border can quickly affect the rest of the supply chain.

Every Border Brings Different Requirements

Moving freight between countries also means navigating different customs procedures, import regulations and documentation requirements.

While many businesses work with experienced freight forwarders and customs clearing agents, cross-border trade still requires careful planning. A missing document, an incorrect tariff code or an unexpected regulatory requirement can delay an entire shipment.

As companies expand into regional markets, understanding these operational differences becomes just as important as understanding the customers they’re supplying.

Infrastructure Doesn’t End at the Port

South Africa has one of the region’s most developed logistics networks, but regional trade depends on much more than local infrastructure.

Road conditions, rail connectivity, border facilities and transport corridors all influence how efficiently goods move once they leave the country. A well-managed warehouse or an efficient port operation means little if the next stage of the journey becomes a bottleneck.

That’s why logistics businesses are increasingly looking beyond individual facilities and considering the performance of the entire transport corridor.

Opportunity Doesn’t Stop at the Border

There’s no shortage of opportunity for businesses looking beyond South Africa’s borders. Regional trade continues to grow, and agreements such as the African Continental Free Trade Area (AfCFTA) are helping create a stronger foundation for doing business across the continent.

The bigger challenge is making those opportunities work in practice. A trade agreement may make it easier to do business on paper, but goods still need to clear borders, travel along reliable transport corridors and arrive on time. That’s where logistics becomes the difference between opportunity and reality.

Regional trade will continue to evolve, but one thing is unlikely to change. Businesses will always depend on supply chains that can move goods across borders efficiently, consistently and with as few delays as possible.

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Logistics

What Makes a Warehouse Efficient?

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Admin

Walk into two warehouses of a similar size and, at first glance, they may look much the same. The shelving is in place, forklifts are moving and orders are being prepared for dispatch. Spend a little more time on the floor, however, and the differences quickly become apparent. One warehouse operates with purpose, while the other is constantly working to recover from delays, misplaced stock and bottlenecks.

Efficiency isn’t simply about moving faster. It’s about creating an environment where people, processes and technology work together to keep goods moving consistently from the moment they arrive to the moment they leave. As supply chains become more complex and customer expectations continue to grow, an efficient warehouse has become one of the strongest assets a business can have.

Good Warehouse Design Reduces Unnecessary Movement

Every extra step inside a warehouse takes time. When employees have to travel long distances to retrieve stock or forklifts regularly cross paths with picking teams, productivity quickly starts to suffer.

An efficient warehouse is designed to keep movement to a minimum. Receiving areas, storage locations, picking zones and dispatch bays are arranged to support the natural flow of goods through the facility. The goal isn’t to rush people from one task to the next. It’s to remove the obstacles that slow them down in the first place.

Knowing Where Stock Is Matters

Most warehouse delays don’t start when an order is placed. They begin much earlier, when inventory records don’t match what’s actually sitting on the shelves.

Having an accurate view of stock allows warehouse teams to pick orders with confidence, replenish inventory before shortages occur and avoid unnecessary delays. Barcode scanning, warehouse management systems and regular stock checks all help create a clearer picture of what’s happening inside the warehouse, making it easier to plan ahead instead of constantly reacting to problems.

Experienced Teams Keep Operations Running

Technology has changed the way warehouses operate, but it hasn’t changed the importance of the people working inside them. Experienced warehouse teams know how to manage busy periods, solve unexpected problems and keep orders moving when the day doesn’t go exactly as planned.

Clear processes, ongoing training and good communication often make a bigger difference than people realise. Even the most advanced warehouse systems rely on teams using them effectively, which is why investing in people remains just as important as investing in equipment.

Technology Supports Better Decisions

Warehouse technology has come a long way over the past decade. What was once used primarily to record stock movements is now helping businesses understand how their operations perform throughout the day.

Warehouse management systems, real-time reporting and automated data collection give managers better visibility across the facility. Instead of waiting for problems to appear, they can identify congestion, monitor inventory trends and make informed decisions that keep operations running smoothly.

A Warehouse Is Only One Part of the Journey

An efficient warehouse doesn’t just improve what happens inside its own walls. It helps trucks load on time, orders reach customers sooner and the wider supply chain run more smoothly. That’s why warehouse efficiency is about more than storage or speed. It’s about creating an operation that businesses can rely on, even when the day doesn’t go exactly to plan.

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