Process efficiency gains make processing and delivery simpler and smoother for a leading South African tea brand

the challenge

ALPAL Freshpak Case Study - What was the challenge?

National Brands Limited (NBL) receives 56 ton of rooibos tea from Rooibos Ltd every week, and packs 11 000 kilograms of rooibos tea per day under the Rooibos, Freshpak and Eleven O' Clock brands.

They were experiencing numerous challenges with the handling and processing of Rooibos tea, including:

  • Poor space utilisation of their facilities due to the lack of stackability of unprocessed stock.
  • High waste management requirements.
  • Poor load stability on pallets.
  • Extensive manpower requirements within the factory.

the solution

ALPAL Freshpak Case Study - What was the solution?

After considering all their needs and requirements, TrenStar introduced the ALPAL packaging system into Rooibos Ltd and NBL’s supply chain. The ALPAL unit is designed to carry bulk rooibos tea between Rooibos Ltd in Clanwilliam, Western Cape, and NBL's Durban factory. Since using the ALPAL packaging system, NBL received the full benefits attached to this highly versatile reusable packaging.

Rooibos Ltd invested in 500 ALPAL units to replace the wooden pallets and disposable paper bags. Before ALPAL, Rooibos Ltd would deliver their tea to the NBL factory on wooden pallets carrying 30 paper bags containing 30kg of rooibos tea each, shrink wrapped together per load of 900kg.

With the ALPAL unit, Rooibos Ltd can now supply NBL with 500kgs of rooibos tea packed into one single unit.

the results

ALPAL Freshpak Case Study - What was the result?

Waste reduction: with ALPAL Rooibos Ltd can supply NBL with 500kgs of rooibos tea packed into one single unit. No paper bags and shrink wrap material are involved in the process anymore, significantly reducing their waste.

Improved storage space: NBL has now gained load stability and increased stocking height to 2 units high, allowing them to stack and optimise their space utilisation.

Handling: Forklifts can be used with ALPAL, reducing the manpower required from 6 to 1.

Decanting: The ALPAL unit offers ease of use with a bottom emptying option, making decanting easier. Instead of manually transporting loads and emptying bags, ALPAL reduced the decanting time from 40 minutes to 6 minutes for a load of 500kg, or a 566% time reduction.

Reverse Logistics: NBL has seen some improvements in truck utilisation, increasing from 25 to 28 ton.

what our client said:

"TrenStar and ALPAL have revolutionised the world of packaging for National Brand Limited."