Geralda JSC

Geralda

Founded in 1995 as a family-run business, Geralda has grown into the largest candle manufacturer in Lithuania, serving customers around the globe. The company produces over 600 types of candles using soy wax, paraffin, and palm oil—involving glass, plastic, or tin containers. Geralda’s production is highly automated, adheres to strict quality and environmental standards, and is firmly committed to sustainability. From recycled materials and bio-based coatings to products certified with the Nordic Swan Ecolabel, sustainability is built into every layer of the operation.

Processes

Production runs in small batches on manufacturing lines with varying throughput capacities, each aligned with seasonal demand fluctuations. Predefined rules determine which products can be processed on which line, since even identical items may require different processing times depending on the line. Geralda uses over 1 000 different raw materials—core materials like wax and containers, are typically sourced one to two months in advance to maintain consistent production flow.

Before Implementation

Before Asprova, Geralda relied on Excel for production scheduling—a manual process that consumed several hours a day, yet delivered only coarse, error-prone, and inflexible results. Handwritten records of production status and progress made coordination between scheduling, production, and accounting slow and inefficient.

Despite intensive daily effort, synchronizing production and sales remained nearly impossible. Raw material purchasing was based on rough estimates rather than actual needs—driving up inventory and costs, stretching the company’s financial resources. An influx of last-minute customer changes, along with a growing number of small rush orders, pushed the manual scheduling process to its limits. Updates lagged behind, and production schedules couldn’t adapt. The result: late deliveries and inefficient use of production capacity. Shift planning was another challenge—staffing needs were nearly impossible to anticipate.

Geralda x Asprova

Since 2010, Geralda has relied on Asprova APS to schedule candle production. Fully integrated with the company’s ERP system and MES, Asprova automates the entire scheduling process—from demand forecast to sequencing.

It Asprova generates a detailed, sequential schedule and precise work instructions for each resource, based on the calculated sequence. All process and scheduling constraints are mapped within the system, including resource capabilities, alternative routes, and finite capacities. The scheduling logic is fully customizable, with flexible standard parameters. Production orders and BOMs are managed directly in Asprova APS.

Asprova calculates raw material requirements days, weeks, and months in advance. Work instructions are automatically exported to an SQL database and stored on-site. Handheld scanners record production results directly on the shop floor, and this data is transferred back into both the ERP and Asprova. The production schedule is dynamically updated—accounting for deviations such as delays in operations. Rescheduling with current production data takes less than a minute, giving Geralda the flexibility it needs.

The result is a precise and transparent production schedule that is both realistic and feasible. Asprova provides reliable delivery forecasts, supports bottleneck identification, and delivers powerful tools for simulation and visualization. Decisions are made much faster. Scheduling, which once took up to four hours, now takes just 20 minutes. With Asprova APS, Geralda benefits from more precise scheduling—including shift planning—an extended scheduling horizon, and significantly improved processes. Asprova synchronizes production and sales and generates detailed procurement plans based on calculated raw material requirements. As a result, Geralda has greatly reduced inventory s and achieved lasting gains in resource efficiency.