How Lemonpath helped Bluetree meet seasonal demand with precise packing, barcoding, and retail-ready execution.
14m Gift sets packed each year
99% Packing Accuracy
24,900 sq ft of warehousing space
To effectively mange the the receipt, storage, quality control, and production of 100,000 componentry items across three ale variations, ensuring correct placement, fitment, box build accuracy, full traceability, BBE Controls and on-time delivery of finished goods to Tesco Hubs.
Receive all stock - circa 100K componentry items for three ale variations, booking receipts into the WMS System
Conduct quality checks on all incoming items to confirm this is no damage or contamination
Allocate appropriate storge space for componentry and finished goods
Generate gold seal samples for production specifications and submit for client approval prior to production.
Utilise detailed production plan using the delivery dates advised by BlueTree
Generate packing picks for requires stock, ensuring BBE dates exceed six months from the expected in-store delivery date.
Allocate and secure staff, QC and service support for the production run.
Perform QC checks during production for correct placement, box build and ale variations
Record BBE and batch codes for each product produced to maintain traceability
Store Finished Goods securely until dispatch
Dispatch as per required schedule, generating goods-out paperwork for finished goods.
A structured, end-to-end workflow established to manage a high-volume componentry, multiple variations and stringent QC requirements. By integrating WMS controls, comprehensive quality checks, production planning, staff allocation, and traceability processes, the operation ensures:
Accurate assembly and box builds
Compliance with client-approved specifications
Robust traceability for potential recalls
Efficient and timely delivery to store
This approach guarantees product quality, operational efficiency, and reliable execution across all three ale variations.
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