BlueSun success story: co-packing of detergent and fabric softener promotional packs integrated with SAP

Co-packing of detergent and fabric softener promotional packs for BlueSun, with SAP integration, a custom sleeve, full traceability and performance measured with OTIF and SLA. An operation built to keep pace with the promotion’s success, which has tripled its volume in a year.

BlueSun’s logistics infrastructure and operations

Sector and activity

BlueSun is a home care company whose detergents and fabric softeners are on the shelves of major retailers. Its promotions combine products in a single pack to gain visibility and turnover at the point of sale.

Operational location

Grupo Akoma’s own centres in the province of Barcelona, with the co-packing operation connected to the customer’s SAP.

Type of operation managed

Co-packing of detergent and fabric softener promotional packs
Development of custom, heavy-duty sleeves and promotional packaging
Order and stock integration with SAP
Traceability of components and finished goods
Performance measured with OTIF and SLA
Handling and assembly of the complete pack
Coordination between Marketing, Operations and Logistics

Operational volume

Promotion volume ×3 in one year
Multi-product promotional packs
Recurring, scalable operations

Initial logistical context

A promotional pack brings together products that arrive separately and must leave as a single sales unit, with its own code, its own packaging and a delivery date committed to the retailer. Any mismatch between physical stock and ERP stock, or any delivery delay, directly affects the campaign.

Initial logistical challenge and critical operational needs

Initial situation and problems

BlueSun needed a co-packing partner to assemble its detergent and fabric softener packs with a custom sleeve, work connected to its SAP system and report against clear service indicators, for a promotion with growing volumes.

Critical factors to be resolved

Connecting the co-packing operation to the customer’s SAP
Applying a custom sleeve with a consistent finish
Ensuring traceability of components and packs
Meeting delivery commitments (OTIF)
Scaling production as the promotion grew

Existing operational risks

Mismatches between physical stock and ERP stock
Packs with an uneven finish on the shelf
Incomplete or late deliveries
Bottlenecks as volume increased

Aim of the project

To set up a co-packing operation integrated with SAP, with a custom sleeve, full traceability and measured service levels, able to grow at the same pace as the promotion.

Promotional co-packing integrated with SAP and measured with OTIF and SLA

Grupo Akoma designed a co-packing operation built around BlueSun’s promotion: orders and stock flow through SAP, the pack is finished with a custom sleeve and every delivery is measured against agreed indicators.

Step-by-step implementation

SAP integration to receive orders and report stock and movements
Receiving and inspection of components: detergent, fabric softener and sleeve
Pack assembly and custom sleeve application with in-line quality control
Identification and traceability of every finished-goods batch
Preparation and shipping with tracking of OTIF and the agreed SLAs

Operational implementation

Co-packing line sized for the promotion
Custom sleeve applied with a consistent finish
Quality control during assembly
Capacity expanded as volume grew

Services provided

Component receiving
Co-packing and assembly of promotional packs
Finished-goods storage
Preparation and shipping to the customer

Technology integration

Order and stock integration with SAP
Traceability of components and packs
Shared OTIF and SLA indicators

Operational results and benefits achieved

The operation has kept pace with the promotion’s growth: in one year volume has tripled, with information synchronised with SAP and service measured with OTIF and SLA.

Performance indicators

×3 promotion volume in one year
Orders and stock integrated with SAP
Traceability of components and finished goods
OTIF and SLA performance measured

Business impact

A promotion that has tripled its volume
Capacity to keep growing
Commitments to retailers met

Operational impact

Physical and ERP stock aligned
Consistent packs ready for the shelf
Planned and measured deliveries

Technology impact

SAP integration
Batch traceability
Service indicator reporting

Strategic value gained

BlueSun has promotional co-packing that is integrated into its system and measured with service indicators, and that has sustained the promotion’s growth to the point of tripling its volume in a year.

Why BlueSun chose Grupo Akoma

Grupo Akoma has been operating since 1991 and has 73,000 m² across four of its own centres in the province of Barcelona, with in-house teams and processes for storage, co-packing and distribution. For BlueSun, this means:

Experience in co-packing and promotional logistics for FMCG
Ability to integrate with the customer’s ERP
Service measured with OTIF and SLA
Capacity to scale when the promotion takes off

A promotion’s success is not measured only by the sales it generates, but by its ability to grow and be repeated.

Grupo Akoma’s view

×3
Promotion volume

Promotional pack volume tripled in one year.

SAP
Integration

Orders, stock and movements synchronised with the customer’s SAP.

Custom sleeve

Detergent and fabric softener packs joined with a sleeve designed for the promotion.

OTIF and SLA

Complete, on-time deliveries, with performance measured against agreed service levels.

About to start?

Case summary

Grupo Akoma handles co-packing of BlueSun’s detergent and fabric softener promotional packs: SAP integration, a custom sleeve, traceability of components and finished goods, and performance measured with OTIF and SLA. In one year, the promotion’s volume has tripled.

Customer	BlueSun
Sector	Home care (detergents and fabric softeners)
Challenge	To assemble promotional packs with a custom sleeve, connected to the customer’s SAP and with measured service levels, for a promotion with growing volume.
Solution	Co-packing integrated with SAP, custom sleeve application, batch traceability and OTIF and SLA tracking.

Results

×3promotion volume in one year
SAPorder and stock integration
OTIF and SLAmeasured performance

Grupo Akoma services applied in this case: Handling and co-packing · Promotional logistics.

Do you have a similar logistical challenge?

If you need promotional co-packing integrated with your ERP, with traceability and measured service levels, we can design a model tailored to your operations.

Ask for logistical advice and we will analyse your situation to propose a clear, viable and measurable solution from the outset.