The Pie Foundry Business Plan — Manufacturing & Operations

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Section 8 · 9 of 23

Manufacturing & Operations

The operational core is a HACCP-compliant central manufacturing facility in Gauteng producing standardised products for every retail channel. Centralised production drives consistent quality, food safety, bulk-procurement savings, reduced store labour, easier franchise management, higher margins, faster new-product development and efficient inventory control.

Facility and capacity

The Year-1 build comprises the facility (R8.0m), production equipment (R5.0m) and a cold-chain fleet (R2.5m), sized for the initial company store and early franchise supply and expandable in modular increments. Production lines cover pastry lamination, filling preparation, assembly, blast-freezing and packing, with capacity added in Years 2–5 as the network and frozen-retail channels scale.

Figure 10. Capital expenditure phasing by category.

Supply chain and quality

  • Bulk procurement of flour, proteins, dairy and packaging on national contracts, leveraging manufacturing scale for input-cost savings passed partly to franchisees.
  • Cold-chain logistics (owned and outsourced) delivering chilled and frozen product to company and franchise outlets and retail distribution centres.
  • HACCP and food-safety management systems, batch traceability and QA laboratories, protecting the premium brand and enabling supermarket listings.
  • ERP, manufacturing-execution and inventory systems (R1.2m Year-1 technology budget) linking production, logistics, retail POS and online ordering.

Operating ramp

Figure 11. Headcount ramp by function.

The organisation grows from 76 employees in Year 1 (executive 4, finance & administration 6, manufacturing 24, logistics 8, retail operations 30, marketing & sales 4) to roughly 278 by Year 5, weighted toward manufacturing and retail operations as volume scales. Franchise outlets add employment beyond these figures at franchisee level.