Ceres Fruit Growers (CFG), one of Tru-Cape Fruit Marketing’s shareholder packhouses, has completed major infrastructure and technology upgrades that confirm its position among the leading apple and pear packhouses in South Africa.
The multi-million-rand investment was driven by sustained growth in volumes as growers continue to invest in new-generation varieties and replace older orchards with more productive ones.
“Ceres Fruit Growers now handles between 130,000 and 145,000 tons of apples and pears annually,” says CFG Logistics Manager Con Louw.
To accommodate the higher throughput, Ceres Fruit Growers increased its physical loading and dispatch capacity by adding dock levellers, expanding load-out areas, and improving pallet handling systems. A new staging area fitted with gravity-fed rollers can accommodate 24 containers simultaneously, improving order picking and reducing forklift movement.
Automation improves productivity
One of the most significant upgrades was the installation of mobile racking storage with capacity for 4,000 pallets, improving space utilisation and stock flow. The company also implemented ViTrax and AppSource pallet movement systems, allowing forklift operators to scan and track pallets in real time using tablets mounted on forklifts.
“The flow through the facility is now far more efficient,” says Louw. “We can prepare loads in advance and respond much faster when shipping schedules change, especially when the Port of Cape Town experiences delays.”
Ceres Fruit Growers is also expanding its recooling capabilities as export protocols and packaging requirements become increasingly specialised. The facility currently operates sixteen cold treatment protocol rooms, steri tunnels, and upgraded holding rooms, with further recooling expansion planned.
Technology and automation play an increasingly important role across the operation, as CFG uses automated palletisers and advanced fruit camera systems.
Ceres Fruit Growers’ packhouse five, which specialises in bi-coloured apples, runs 24 hours a day during peak season and can pack apples into four colour categories with ten count sizes within each category. The packhouse averages 18 tonnes per hour.
“Our aim is to maximise packout percentages while improving productivity and maintaining flexibility for our growers and markets,” says Louw. “There is no such thing as ‘set and forget’ in this industry.”
Ceres Fruit Growers also had to invest in energy resilience, enabling the entire site to operate independently from Eskom through two generators, 5.5 MW of solar capacity, and batteries.
During the season, the company employs more than 1,600 people. Staff dining and relaxation facilities were also upgraded as part of its broader focus on employee well-being, operational excellence, and food safety.
Smarter logistics, greater efficiency
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According to Roelf Pienaar, managing director of Tru-Cape Fruit Marketing, tasked with marketing Ceres Fruit Growers’ apples and pears, the upgrades strengthen the packhouse’s ability to consistently supply global markets with high-quality fruit despite increasing logistical and market pressures.
“As marketers of Ceres Fruit Growers’ fruit, we understand how critical operational efficiency, cold chain integrity, and consistency are in international markets,” says Pienaar. “These investments ensure Ceres Fruit Growers remains globally competitive and well-positioned to support growers as production volumes continue to increase. It also demonstrates the long-term confidence our growers have in the South African apple and pear industry.”
“It is satisfying to see how smoothly everything now operates across the packhouses,” says Louw. “The upgrades have made a significant difference to efficiency, consistent product quality, and the overall working environment.”
For more information, please contact Lucille Botha at lucilleb@tru-cape.co.za or visit www.tru-cape.com. Follow Tru-Cape on X (@TruCapeFruit), Facebook (@Tru-Cape Fruit Marketing), TikTok (@trucape), and Instagram (@trucapefruit).
