In this case study, management consultant Baringa identifies multi-million-pound pharma supply chain savings in just six weeks with Kallikor, a supply chain design platform, demonstrating the benefit of simulation-led analysis in warehousing and logistics operations.
In 2025, Baringa engaged with a pharmaceutical services provider whose European warehouse network was operating with latent capacity. While volumes were expected to grow significantly, parts of the network were constrained in ways that static analysis could not fully explain.
Baringa’s client needed to understand the cost and service implications of reconfiguring its European network to increase capacity utilisation and support future growth safely – and what structural changes might be required – without relying on assumptions or committing capital prematurely.
James Moffatt, Director, Baringa, says, “Existing analysis was insufficient as the company was unable to digitally recreate warehouse setups in enough detail to assess future scenarios. To help meet the firm’s diligence requirements, we engaged Kallikor to build a model of the operations.”
The solution
Baringa partnered with Kallikor to create a simulation digital twin that allowed a range of possible growth scenarios to be tested safely before decisions were made.
Using Kallikor’s Warehouse DesignLab, the team built a detailed operational model of the client’s European warehousing operations, capturing storage, throughput, labour and constraints across four temperature-controlled chambers.
Kallikor enabled Baringa to: analyse current utilisation levels across storage and throughput and test the feasibility of consolidation; develop a range of growth scenarios to model business growth in line with the client’s three-year sales forecast; and devise storage and throughput volume projections across four temperature channels over three-year periods.
Furthermore, Baringa used the advanced technology to run 72 different consolidation scenarios to compare structural options and the client’s operational, financial and service impacts. Further opportunities for improvement were also discovered, including greater throughput and tightly defined CAPEX investments for expanding storage.
Ultimately, Baringa was able to provide a board-ready proposal showing an 18-month payback period within six weeks.
With Kallikor’s simulation-led analysis, Baringa was able to confidently recommend the reconfiguration of the European network. This promised a clear path to achieving operational efficiency and profitability in line with projected growth estimates.
The fully costed and executable business case was delivered in six weeks, recommending targeted CAPEX investment, with the client achieving a multi-million-pound EBITDA uplift and payback in less than 2 years.
James Moffatt, continues, “Thanks to Kallikor’s technology and expertise, we were able to quickly move from first engagement to board-ready business case at unprecedented speed; half the time a project of this nature would normally take. We’re looking forward to working with our client on further projects.”
Jonathan Barrett, Founder, Kallikor, concludes, “This engagement shows how simulation-led experimentation helps organisations unlock growth without flying blind. By testing how systems behave as demand scales, teams can align stakeholders and commit to decisions with confidence.”
