How Repacking Became a Mandatory Retail Requirement and Reduced Logistics Costs
About the Client
The client is a large international coffee manufacturer working with federal retail chains and managing a wide product portfolio. For the company, compliance with retail requirements, supply stability, and operational efficiency are critical.
Challenge
One of the client’s key retail partners introduced a mandatory requirement: the number of units per package had to be changed.
Originally, products were supplied in boxes of 4, 12 or 20 units, while the retailer required a format of 6 units per box.
Importantly, this was not an optional adjustment but a strict retail requirement. Without changing the packaging format, supplying the retailer would not have been possible.
The challenge was further complicated by several factors:
-the need to change packaging format without involving production;
-maintaining compliance with retail requirements without delaying deliveries;
-preserving product quality during repacking;
-organizing a scalable and repeatable process for large, ongoing volumes.
At the start of the project, up to 85% of the product range required repacking into different formats (including conversion from 4, 12, and 20-unit packs into 6-unit packs).
Astros Logistics Solution
Astros Logistics designed and implemented a comprehensive repacking process directly at the warehouse.
Key elements of the solution included:
-setting up a dedicated repacking area;
-developing clear standard operating procedures for handling and repacking;
-implementing quality control at every stage;
-integrating the process into existing warehouse operations without impacting delivery timelines;
-establishing a regular, scalable workflow aligned with shipment schedules.
In addition, Astros Logistics optimized the repacking process.
Initially, all products were repacked into carton boxes. As part of the project, an alternative solution was introduced — using thermofoil (shrink wrap) for part of the product range.
This resulted in the following model:
-75% of products repacked in thermofoil;
-10% repacked in cartons;
-15% did not require repacking.
This approach significantly improved operational efficiency.
Results
As a result, the client achieved:
-full compliance with retail requirements and ensured continuity of supply;
-a scalable and stable repacking process;
-consistent deliveries in the required format without delays;
-reduced operational workload on internal resources;
-cost optimization of approximately 20% compared to a model where 85% of products were repacked in cartons.
This project demonstrates that warehouse logistics can go beyond storage and become a tool for adapting products to market requirements and optimizing operational costs.