Airco Unifies A/NZ Freight Operations and Reduces Manual Effort with Cario
Client: AircoAirco Brands is a 100% Australian-owned and operated company specialising in trade-quality fasteners, tools and compressors. They design, develop and supply a wide range of products including nails, screws, staples, rings, anchors, pneumatic and electric tools, hand tools, compressors. Their portfolio includes multiple trusted sub-brands (e.g. Otter, Senco, Colt, Cobra) and they cater to trade, OEM and DIY/retail customers. |
Industry: Hardware and Industrial Fasteners |
1
integrated freight process across Australia and New Zealand
SAP
and 3PL integration streamlines order fulfillment
40+
carriers managed through a single freight platform
Increased
visibility into freight costs and margin impact
The Problem
As a national supplier of nails, screws, nail guns, and other hardware products to Bunnings and independent hardware stores across Australia and New Zealand, Airco manages a high-volume, complex freight network. Their freight profile includes everything from individual cartons to full truckloads, transported via their own warehouse and third-party logistics (3PL) providers.
Over the years, Airco relied on a mix of 4PL brokers and freight platforms to manage this network, but the fragmented systems made it hard to stay in control.
Each region used different carriers and tools. Freight data was inconsistent. Integration with SAP B1 was limited. There was no straightforward way to track true freight costs or enforce delivery terms with customers. With up to 40 carriers involved, this lack of visibility was starting to cost the business.
The Impact
Managing freight across multiple platforms made it difficult for Airco to get accurate, real-time insights into the “cost to serve”. Reconciling invoices was complicated and carrier performance wasn’t transparent. Additionally, since Australian and New Zealand operations were separate, conducting end-to-end analysis was slow and difficult.
“We were using different freight systems and different cost profiles depending on the day and the shipment,” says Adam Helder, National Operations Manager at Airco. “That made it really difficult to work out our true freight percentage to sales or measure carrier performance in a meaningful way.”
Not only did this restrict their ability to quote freight costs accurately, but it also made it harder to hold customers accountable for agreed-upon delivery terms, such as free-in-store (FIS) thresholds. Human error in dispatch and pricing inputs increased the risk, while the logistics team often received calls from customers chasing deliveries, wasting time on enquiries that weren’t always their responsibility.
The Solution
In 2023, Airco selected Freight People and the Cario platform following a market review. The choice was influenced by Cario’s strong integration capabilities and its proven success in managing freight on both sides of the Tasman.
Cario was able to directly integrate with SAP B1 and Airco’s 3PL provider in New Zealand, creating a single, automated process that covers both countries. Sales order data from SAP now flows seamlessly into Cario, triggering accurate routing, pricing, and carrier allocation without manual input. Tracking data and proof of delivery are automatically fed back, providing everyone from logistics to finance to customer service with a real-time view of freight performance.
This integration eliminated the need to manage two separate freight processes, allowing Airco to streamline dispatch and standardise reporting. A single freight platform also enabled them to finally track key metrics, such as freight cost as a percentage of revenue, and identify where margins were being eroded.
Beyond the system itself, Airco also utilises Cario’s insights to enhance their freight strategy. Monthly reports and structured quarterly reviews help the business identify operational inefficiencies and refine carrier selection. For example, by analysing customer ordering behaviour, Airco can now spot where orders are being placed outside of FIS agreements and adjust account management accordingly.
The Outcome
With Cario, Airco has been able to consolidate and modernise its freight operations. Australian and New Zealand shipments are now handled through a single workflow, integrated into the ERP, with automated routing, quoting, and performance tracking.
The logistics team spends less time manually managing freight consignments and more on enhancing operations. Customers get faster updates and direct access to PODs and ETAs. Freight costs are monitored accurately, ensuring margins are maintained.
Most importantly, the business now has full control over its freight data, and a clear plan to make the most of it.
“The best part of Cario is the combination of strong data and true integration,” says Helder. “It’s given us the visibility we need to challenge ourselves and improve how we operates.”