Inside Juhayna’s “Black Box”

Powering Efficiency and Safety at El Dawleya Plant

Our Contribution to the UN Sustainable Development Goals

At the heart of Juhayna Food Industries’ advanced manufacturing ecosystem lies El Dawleya plant, one of the largest industrial complexes in Egypt and the MENA region. Operational since 2009, the facility is dedicated to the production and packaging of fresh juices and beverages, including Juhayna Juice, Pure, Bekhero, and Oriental drinks. Fully automated and operating with cutting-edge technologies, El Dawleya stands as a model of efficiency, safety, and sustainability.

A key pillar of this operational excellence is the “Black Box” system, a fully automated high-bay warehouse solution introduced in 2018. Designed to handle and store pallets seamlessly during processing and loading phases, the Black Box represents a technological leap in warehouse management and logistics optimization. Since its implementation, the system has consistently delivered 100% on-time-in-full (OTIF) deliveries while achieving zero fatalities, significantly enhancing workplace safety and operational reliability. 

Beyond logistics performance, the Black Box has enabled El Dawleya to optimize storage capacity, resulting in a 32% reduction in reliance on rented warehouse space through better utilization of existing facilities. This has led to tangible operational cost savings while supporting lean and efficient supply chain operations. 

From a sustainability perspective, the Black Box plays a central role in Juhayna’s environmental strategy. By streamlining pallet handling, reducing material movement, and minimizing manual intervention, the system contributes to lower energy consumption, reduced waste, and improved carbon efficiency. These achievements reinforce El Dawleya’s position as a benchmark for sustainable industrial operations, supported by international certifications such as FSSC 22000, ISO 14001, ISO 45001, and ISO 50001. 

As Juhayna continues to scale its operations, the Black Box at El Dawleya stands as a powerful example of how digital transformation, automation, and sustainability can converge to deliver superior operational performance while maintaining the highest standards of safety and environmental stewardship.