Silafrica: Pioneering sustainable packaging solutions in Africa
Silafrica workers on In Mould Labelling (IML), where yogurt cups start their journey. These cups are recovered after their end of use and recycled to make the Silafrica multipurpose crates.
Packaging plays a crucial role in today's economy, serving as a protective barrier for products and also as a vital component of branding and sustainability, influencing consumer choice, enhancing shelf appeal and ensuring product safety during transit.
In an age where environmental awareness is paramount, innovative packaging solutions are essential to minimise waste and encourage recycling. As companies strive to meet consumer demands for sustainability, the packaging industry is evolving to incorporate environmentally friendly materials and practices that align with a circular economy.
This shift not only supports brand loyalty, but also contributes to a healthier planet, making packaging a key player in both commerce and environmental stewardship.
A leader in sustainable packaging and innovation in Africa, Silafrica specialises in high quality rigid and flexible packaging products across the eastern and central Africa.
Founded in the 1960s through a unique partnership between two families linked by marriage, the company has successfully combined market presence with technical expertise.
Initially responding to a pressing need for basic plastic products, Silafrica has since evolved into a dynamic company that is revolutionising the regional packaging market.
From Tanzania, Silafrica expanded to Kenya, Ethiopia and most recently Mozambique. The family also ventured into plastics factories in the UAE, Uganda and Nigeria, but these operations did not live up to expectations and were subsequently closed.
According to Akshay Shah, group executive director, the initial market lacked basic plastic products such as footwear, furniture, toys and baby bottles, which prompted the manufacturing initiatives.
“The initial focus on basic plastic products was a response to a clear market gap. In the 1960s, consumers in East Africa lacked access to affordable, high-quality plastic goods,” he says.
Akshay Shah, the Group Executive Director of Silafrica, a company that specialises in high-quality rigid and flexible packaging products across the Eastern and Central African regions displays one of the plast crates
However, a strategic shift towards the production of plastic packaging opened up significant growth opportunities, driven by increasing demand from a range of industries, including food and beverage, cosmetics and pharmaceuticals.
This partnership capitalised on the economic opportunities and laid the groundwork for acquisitions and the establishment of Greenfield factories that have fuelled Silafrica's growth over the years.
“Our vision remained clear: to address the significant gap in the local market for affordable, high-quality plastic goods,” he says.
Securing the initial funding for Silafrica involved leveraging savings from existing trading businesses within the families. This funding facilitated the start of production and subsequent expansion.
The commitment and entrepreneurial spirit of the founding families laid the groundwork for a thriving enterprise.
At the heart of Silafrica's operations is a complex process that transforms raw materials into finished packaging products. The process starts with plastic polymers in granule form, which are fed into machines that melt the material mainly through friction. Once melted, the plastic is either injected into moulds under high pressure or extruded into free forms before being moulded.
The cooling process is crucial; the moulds are kept at cold temperatures using chilled water to ensure that the hot plastic retains its shape as it cools.
Safety regulations
“Quality control is paramount, with rigorous checks on dimensions, weight, colour, shape, and strength, ensuring that products meet industry standards and safety regulations for various applications,” says Mr Shah.
Managing distribution in eastern and Central Africa has its own challenges. Packaging must be delivered to customers in time, which requires efficient logistics and strong partnerships with local recyclers. By working with local recyclers, Silafrica ensures that recycled materials come from the packaging it produces, reinforcing its commitment to sustainability.
"We strategically export non-bulky packaging to ensure that the landed costs remain competitive in destination markets, as this approach helps manage logistics costs and minimises price markups," he says.
Operating in the East African market is not without its challenges. A key internal hurdle is the inconsistent supply of reliable electricity, which is essential for smooth operations.
The availability of clean electricity remains a significant challenge in the manufacturing landscape in several countries. In addition, the rising cost of capital and electricity, coupled with currency devaluation against the US dollar, pose ongoing operational difficulties.
To address these challenges, Silafrica is adopting proactive strategies.
Mr Shah says that by implementing a comprehensive operating model known as The Silafrica Way, the company focuses on transparency, regular audits and the use of Internet of Things (IoT) technologies to monitor manufacturing efficiencies. This holistic approach helps to minimise disruptions and maintain reliable supply chains.
Silafrica recognises the critical issue of plastic waste and advocates for increased awareness, behavioural change and supportive legislation to address plastics management.
As a global signatory to the Ellen MacArthur Foundation and a founding corporate member of various Packaging Producer Responsibility Organisations (PROs), Silafrica is committed to creating 100 percent recyclable plastic packaging.
With a team of 700 employees and a portfolio of over 200 products, the company's innovation strategies focus on increasing the use of recycled materials in its packaging solutions.
Innovative packaging initiatives
“We have increased our use of post-consumer recycled (PCR) materials from 19 percent to 32 percent, and we are on track to exceed 40 percent by next year. Additionally, we have innovative packaging initiatives aimed at raising PCR usage to 60 percent by 2030,” he says.
As for biodegradable materials, he says they are not supported because they can break down into microplastics.
“We believe that if a material cannot be collected, sorted, and recycled effectively, it is more sensible to choose options that naturally compost without contributing to microplastic pollution.”
Innovation at Silafrica is intrinsically linked to sustainability. The company strives to develop packaging solutions that are not only innovative, but also environmentally friendly and economically viable.
Each new product design is assessed for its sustainability impact, ensuring that it is in line with the company's commitment to responsible manufacturing practices.
Success stories abound, with partnerships leading to innovative solutions such as trackable crates and sustainable yoghurt cups.
Silafrica recognises that a commitment to ethical practices and sustainability must permeate every level of the organisation. To ensure alignment with its core values, the company has implemented several initiatives, including a whistleblower policy, blue certifications and ethical audits.
It is also exploring B Corp certification, which could further strengthen its commitment to social and environmental responsibility.
“Looking ahead, our plans include increasing the use of post-consumer recycled (PCR) and post-industrial recycled (PIR) materials in our packaging solutions. We are also exploring new markets in Zambia, Mozambique, and South Africa, along with potential investments in advanced technologies that support sustainable manufacturing practices," he says.
As Silafrica continues to evolve, the focus remains on fostering strong relationships with clients and partners while maintaining a commitment to sustainability. By addressing the plastic waste crisis and promoting a circular economy, Silafrica aims to be at the forefront of responsible packaging solutions in East Africa and beyond.
