The Partnership for Supply Chain Management (PFSCM) collaborated with global logistics services provider Logenix International to optimize a large air shipment of tuberculosis (TB) diagnostic products originating from India and destined for Nigeria.
Through transport planning and load optimization activities, PFSCM identified opportunities to improve palletization for the more than 500 pallets of mixed time and temperature-sensitive TB products, thereby saving air-freight costs and reducing lead time.
PFSCM Transportation Network Manager David Thompson-Mensah explains that as a standard good practice, PFSCM undertakes transport planning and load optimization for large, urgent, and complex orders but also intervenes in the logistics process when suboptimal packaging, palletization, or shipment modes have been identified.
He notes that in the scenario of the TB products for Nigeria, PFSCM had to deliver tens of thousands of products—which included hundreds of micro polymerase chain reaction (PCR) analyzers, chip-based real-time PCR tests, sample pretreatment packs, amplification reagents, control kits, sample preparation kits, field cases, and solar panels (hazardous goods)—on time and within budget.
“To achieve timely delivery, we had to use charters, and to stay within budget; we had to determine how the hundreds of pallets could be optimized to make the best use of the volumetric area for which we were charged.”
He expands on the charges by explaining that air carriers charge by volumetric or actual weight, depending on which is more expensive.
“We knew we had to investigate the palletization to fully use the charters’ available height or volumetric area.”
Further, he explains that the initial palletization entailed a nonstackable configuration amounting to 696 m3, enough to fill two large freight airplanes at a significant cost.
“When shipping goods in small volumes, a nonstackable pallet configuration is not generally an issue, and often, no alternative options exist. However, when large quantities are shipped simultaneously, space needs to be used optimally for affordability and sustainability, moving as much in as few trips as possible.”
Photos 1 and 2: Nonstackable (unoptimized) pallet configuration with oversized pallets.
He continues that PFSCM and Logenix International determined that a stackable configuration would be possible, provided that the pallets were either customized or reconfigured to not compromise the integrity of the cartons while double stacked.
“There are other ways to optimize loading, such as using different packaging or redesigning the loading pattern of the boxes, but under critical time pressure, we recommended stacking two pallets on top of each other, using the entire paid-for volumetric area.
“This quick solution also meant that we did not have to redo all the shipping documents, a lengthy and complicated process.”
He adds that Logenix International reinforced the bottom pallets and thoroughly tested the stacking design. Once the integrity of the palletization was confirmed, the pallets were double-stacked and shipped using two small charter aircraft. Only two surplus pallets had to be moved in the belly of a commercial airline. The pallet optimization reduced the initial shipping load from 581 to 525 pallets, or 696 m3 to 529 m3.
“The charter options offered us more scheduling flexibility and resulted in cost savings and reduced lead times, enabling the critical TB health products to be delivered within an acceptable time frame,” Thompson-Mensah concludes.
Meanwhile, Logenix International Project Manager Tucker Morgan added that Logenix International is accustomed to dealing with unique logistics problems, and though the consolidation efforts posed a significant challenge, the company quickly found innovative loading solutions and ramped up stakeholder communications.
“By prioritizing constant communication, we built upon our relationships with PFSCM and its suppliers to improve operational efficiency and ensure both time savings and cost-effectiveness.”
Photos 3, 4 and 5: The reinforced pallets allow for stacking. The stacking configuration can be seen here.
Beyond collaborating with the manufacturer and Logenix International, PFSCM also worked closely with its in-country Strategic Advisor, Sunday Aguora, and the Nigerian recipient, the National Tuberculosis, Leprosy and Buruli Ulcer Control Programme (NTBLCP), to coordinate the importation and tax waiver documentation, pre-inspections, and quick clearance of the goods upon arrival at the Lagos airport.
PFSCM Logistics Specialist Hanne Lammassaari says that importation regulations for Nigeria are extensive and detailed, and she explains that PFSCM and Aguora worked closely with the recipient and Logenix International to ensure the hundreds of documents were completely accurate and filed timely.
“Despite the many intricate procedures for importing into Nigeria, we enjoyed a near-flawless process which can mainly be attributed to the proactive monitoring of our in-country advisor and the professionalism of the recipient and its responsive partners, including the clearing agent and supplier.”
Meanwhile, Lammassaari confirms that the charters landed in Nigeria on 1 and 4 November 2024, respectively.
The recipient will move the products from the warehouse to more than 300 locations throughout Nigeria to support TB programs.
- Flexible scheduling: Charter flights provide flexibility, allowing clients to customize flight schedules, including departure times, arrival times, and destinations, to align with their operational needs.
- Direct travel: With charter flights, journeys are typically non-stop, ensuring faster and more efficient transport.
- Specialized cargo and emergency transport: Charter aircraft are ideally suited for transporting specialized cargo, including medical supplies, and are indispensable during emergency situations where time is critical.
- Cost efficiency and reduced operational stress: Shippers can achieve cost efficiencies through lower overall flight charges compared to many commercial flight options. Moreover, the streamlined nature of charter services enhances convenience, reducing logistical complexities and stress.
- Global accessibility: Charter aircraft can reach remote and underserved regions worldwide, offering a crucial advantage for NGOs and other organizations requiring access to secluded areas for humanitarian or health-related missions.
This unique combination of flexibility, efficiency, and accessibility makes charter flights an invaluable tool in addressing urgent logistical challenges.
Photos 6, 7 and 8: The stacking configuration can be observed during the offloading in Nigeria at the Lagos airport.