Bromor Foods, for example, is among an increasing number of companies that's solved its logistics problems by using the computerised packaging design, palletisation and space optimisation program from Cape Systems, marketed in South Africa by BCA Software (a division of BCA Filmaster).

Guy Morrison, chief chemist, outlines three initial objectives: firstly, to ensure that each pallet configuration was the most efficient at each site; secondly, to standardise warehouse racking where possible and then to standardise pallet patterns; and thirdly, to alter patterns where pallet overhang was a problem. 'We still have some products that overhang,' Morrison concedes, 'but reduction in overhang is more costly in terms of warehouse space than the cost of damage resulting from overhang.'

However, there's a new way of maximising pallet efficiency without overhang and that's by redesigning bottles and jars - a project that's currently taking place.

He cites an example of a typical exercise conducted using the Cape System.

Bromor's Baking Powder required new marketing impetus and case and pallet configurations were taken into account when redesigning the bottles. Effectively, by changing the case size through better product design, space utilisation has been improved by 40,7% (which represents similar savings on packaging and distribution costs).

'The Cape System is so quick to use that it takes only a couple of minutes to agree to a new design concept,' Morrison says. 'In most cases, we merely state the design parameters of length and width (height is predetermined by the type of marketing appearance required and store shelf height requirements).'

The program is used primarily to design outer cases and optimise pallet loads. Whereas before it could take an hour to calculate outer case designs, now it takes only minutes, and enormous amounts of money are saved in all steps of the supply chain.

In setting up the pallet changes, computer generated diagrams assist in obtaining consensus from distribution and sales personnel, and, by being able to compare visually present and proposed designs, it's easy to demonstrate technical advantages.

These days, Bromor's production and warehouse facilities are so accustomed to receiving these palletisation diagrams that they won't commence production without them!

Packaging material usage and pallet-loading efficiency can be improved, resulting in significant cost savings.

It's estimated that by putting more product into the same space companies can save an average 10% on storage and distribution using the CAPE program. This figure can often be as high as 25% - sometimes even more.

Other benefits include higher productivity, more efficient use of space and materials, improved logistics management and, ultimately, higher profits.

Printouts, with multiple views of the product, case and pallet load can be used as a marketing tool or as part of a specification to assist assemblers in the warehouse. One view may show how primary packages are arranged in the outer case, another may show each layer of the loaded pallet and a third might show the fully loaded pallet.

CAPE PACK and the 3D imaging program are further examples of Cape Systems' commitment to developing state-of-the-art programs and maintaining its position as the world's leading supplier of packaging design and pallet-loading software.

Companies involved in manufacturing and distribution of products - from multinationals to independent operators - simply can't afford to ignore this powerful, yet inexpensive software technology.