Pioneering the future: How automation is redefining distribution excellence at Longmeadow

Three years ago, our Longmeadow Distribution Centre in Gauteng faced a challenge familiar to many growing businesses: demand was increasing rapidly, but available warehouse space was not. To keep products moving, we relied on two external warehouses, adding complexity, increasing transport distances and driving up costs.

Expanding the footprint seemed like the obvious solution. More warehouse space. More trucks. More infrastructure. Instead, the team asked a different question: how could we unlock more capacity from the space we already had?

The answer has transformed the way we operate.

Today, 17 laser-guided automated vehicles (LGVs) move seamlessly through the warehouse, helping us create space for an additional 6,804 pallets without the need to expand the building.

What began as a space constraint became an opportunity to reimagine how a modern supply chain can work, delivering greater efficiency, sustainability and capability.

Consolidation that works

Longmeadow is our largest distribution centre in the region, serving as a hub that connects products to consumers across multiple markets.

When demand grew, we relied on external warehouses to create additional capacity. But this meant more truck journeys, longer travel distances and a bigger environmental footprint.

By installing densified drive-in racking and 17 electric LGVs, we increased storage capacity by 6,804 pallet positions without adding any extra building space. We also consolidated operations from three sites into one efficient hub.

Bringing operations together allowed us to close two external warehouses and eliminate unnecessary delivery routes. This means fewer truck trips, fewer kilometres travelled and lower emissions. The LGVs run on lithium-ion batteries, replacing diesel-powered forklifts and helping us reduce our environmental impact while improving efficiency.

Longmeadow is our largest distribution centre in the region, serving as the hub that keeps products flowing to multiple countries.

Precision that matters

Each LGV is connected to our warehouse management system, allowing it to receive instructions in real time, select the best route and move pallets accurately and efficiently around the clock. This technology has helped us achieve a 99.8% accuracy rate while reducing product damage, stock losses and inventory discrepancies. 

As a result, products reach consumers seamlessly. Reliable deliveries help keep shelves stocked and ensure products are available when consumers need them.

Changing roles, not eliminating them

When people hear "automation", they often worry about job losses, but that is not what unfolded at Longmeadow.

While LGVs now handle many of the repetitive and physically demanding tasks, our people remain at the heart of the operation. Team members who once operated forklifts moved into roles such as Technical Operators, overseeing automated systems, managing exceptions and supporting operational improvement.

The transition was not without challenges. Integrating our SAP system, E80's warehouse management software and the LGV fleet required months of design, testing and calibration. Productivity slowed in the early weeks as teams adapted to new systems and workflows, and unexpected issues had to be resolved in real time.

But our people did more than adapt. They worked alongside technical teams to solve problems, refine processes and find practical solutions. Through resilience, collaboration and hands on experience, they developed valuable new skills in automation, problem solving and operational excellence.

As confidence grew, so did performance. Productivity recovered and eventually exceeded previous levels.

Technology enabled the change, but our people made it possible.

Part of something bigger

What we’ve built at Longmeadow connects to broader investments across Nestlé ESAR. The South Africa Centre for Industry and Technology is developing local innovation capabilities. Renewable energy installations are reducing environmental footprint at our production sites. Skills development initiatives are strengthening capabilities across the region.

Longmeadow demonstrates how operational excellence can improve efficiency, reduce environmental impact and create new opportunities for people.

The work continues

The LGVs continue to keep operations moving efficiently, while our teams look for new ways to improve performance.

The lessons learned at Longmeadow are already helping to shape future improvements across the region. As we continue exploring opportunities in automation, renewable energy and advanced analytics, our focus remains the same: building a more efficient, sustainable and resilient supply chain.

Every day, thousands of products leave Longmeadow on their journey to homes, schools and communities across Eastern and Southern Africa. Behind each delivery is a network of people, technology and innovation working together to ensure families can access the food and beverages they rely on.

At its heart, this transformation is about more than warehousing and logistics. It is about helping us fulfil our purpose of unlocking the power of food to enhance quality of life for everyone, today and for generations to come.

We are proud of how far we have come and excited about what comes next. Because every improvement we make strengthens our ability to serve consumers, support communities and deliver trusted nutrition across the region.