South African companies are under constant pressure to optimise processes and increase efficiency. While many elements contribute to a productive workflow, one frequently ignored issue has enormous potential: packaging inventory planning.

To put it simply, having a clear strategy and plan for your bulk packaging will ensure that you always have stock and can store and transport your goods with fewer delays. Stores and warehouse managers need to optimise their processes by compiling a well-thought out inventory plan.

Custom Bulk Bags is a reputable South African producer of bulk bags and is dedicated to providing high-quality packaging solutions that are personalised to your specifications. We produce up to 3.5 million bulk bags per year and our products can safely hold between 500kg and two tonnes of material per bag, depending on your needs. 

How to optimise your bulk bag storage space

The effects of inefficient packaging inventory management

Many companies have ineffective packing inventory management. This can create a few problems, including the following:

  • Stockouts and shortages – Running out of essential packaging materials can cause manufacturing delays, missed deadlines, and dissatisfied customers. Overstocking, on the other hand, ties up money, raises storage expenses, and puts products at danger of obsolescence due to material changes.
  • Disorganised storage – Inefficiently organised warehouses make it time-consuming and difficult to find th
  • Poor lead time management – Inaccurate lead-time estimates for ordering materials might lead to stockouts or overstocking.
  • Lack of data-driven decision-making – Without trustworthy data on inventory levels and usage patterns, it is impossible to make educated purchasing and storage decisions.

These inefficiencies can have a considerable impact on earnings and competition in South Africa’s competitive market. So, how can your business benefit from better inventory planning?

Additional ways to protect sensitive products from moisture
Additional ways to protect sensitive products from moisture

Effective packaging inventory planning benefits 

Implementing strategic packaging inventory planning provides a number of advantages for companies. Firstly, by reducing stockouts and overstocking, your company can save on material costs, storage fees, and labour involved with managing extra inventory.

Next, it can improve lead time management. Accurate lead-time forecasting enables timely material ordering, avoiding both stockouts and wasteful overstocking. This creates an enhanced production flow, where organised warehouses and efficient material retrieval can reduce production delays and improve workflows.

Lastly, efficient inventory planning will improve client satisfaction. Consistent availability of packaging materials leads to timely deliveries and provides a good market reputation among your customers and clients.

All of these benefits rely on data-driven decisions. By leveraging your data from your inventory management systems, you can make better decisions about purchasing, ordering and storing your packaging materials.

Used bulk bags under covers in the Custom Bulk Bags warehouse

Steps to creating a solid inventory plan

There are five important steps for adopting strategic packaging inventory planning:

1. Conduct an inventory audit – First, determine your current inventory levels. This includes looking at the types and amounts of packing materials, their locations, and consumption trends.

2. Implement inventory management software – An inventory management system (IMS) enables real-time data tracking, stock level monitoring, and utilisation insights.

3. Forecast demand – Analyse your previous sales data, production schedules, and seasonal trends to anticipate future need for packaging materials. This enables proactive ordering and prevents stockouts.

4. Define your inventory levels – Set your minimum and maximum stock levels, including reorder points (ROP) for placing new orders. Maximum stock levels (MSL) will enable you to avoid overstocking and increased storage costs.

5. Improve storage and retrieval – Organise the warehouse efficiently for simple access and retrieval of packing supplies. Consider creating a first-in, first-out (FIFO) system to ensure materials are used in the order they were received, hence reducing the risk of obsolescence.

By applying strategic packaging inventory planning, your business can achieve a competitive advantage in the South African market. These methods result in significant cost savings, increased efficiency, and improved customer satisfaction, ultimately leading to increased profitability and long-term growth.

Custom Bulk Bags is able to assist your company with its bulk packaging needs and inventory management. After a consultation with one of our experts, we will be able to determine your needs and ensure that you always have bulk bags in stock at the right time. For more information about our bulk bags or to get advice on the ideal design specifications, please contact us today.


Custom Bulk Bags is a leading South African manufacturer of woven polypropylene bags for various industries, such as mining, chemicals and food. We are able to produce over 3.5-million bulk bags per year, keeping our customers in stock at all times. Our bags adhere to the highest levels of quality as a result of our stringent in-house testing and quality control programmes.

Custom Bulk Bags holds ISO 9001 certification and we currently have a number of UN-certified designs. We are a Level 2 B-BBEE manufacturer and supplier and fall under the ownership structure of Deneb Investments Limited. For more information on our products, contact Follow us on Facebook, LinkedIn and Instagram for our latest news and industry insights.