Build a chemical plant system around your formulations, your batches and your hazard records.
A chemical plant works from a formula. Raw materials are charged into a reactor or a blender, a batch is made, and the QC lab decides whether it can be released. The formula, the batch and the test result must stay together.
Many of the materials are hazardous. Each has a safety data sheet, a storage class and handling rules. Finished products carry labels that depend on the contents and the country of sale.
GullySystem could build a system that holds the formulation, the batch record, the QC release and the safety data together. Every drum would be traceable to the batch and the raw material lots.
Chemical businesses we could build for.
A resin maker running reactors and a cleaning product blender filling cans handle batches and hazards differently. The first needs process control records and the second needs fast pack changes.
- Industrial chemical manufacturers
- Specialty chemical manufacturers
- Adhesive manufacturers
- Solvent manufacturers
- Water treatment chemical manufacturers
- Industrial cleaning chemical manufacturers
- Resin manufacturers
- Paint and coating manufacturers
- Pigment and dye manufacturers
- Lubricant blenders
- Agrochemical formulators
- Textile and leather chemical makers
- Construction chemical makers
- Chemical traders with blending units
- Toll manufacturers
- Export chemical suppliers
The modules, and what each one covers.
Nothing here is a fixed package. Each module is built, left out or changed to match how your organisation already works.
Raw material and product master
Every material has a grade, a hazard class and a unit of measure. The master carries them into each later record.
- Material name and trade name
- Chemical name and CAS number
- Grade and purity
- Hazard class and storage class
- Unit of measure and density
- Supplier specification
- Safety data sheet version
- Shelf life and retest date
- Finished product code and pack sizes
Formulations and recipe versions
A formulation is a list of materials with quantities and process steps. It changes over time, and each version is kept.
- Product and formulation version
- Materials with quantity per batch size
- Tolerance on each material
- Process steps, temperatures and hold times
- Yield expected
- Approval of a new version
- Customer-specific formulations kept confidential
- Cost per kilogram or litre
- Scale-up from laboratory to plant batch
A formulation is often a trade secret. Access can be limited to named people, and the full recipe can be hidden from operators who only need quantities.
Inbound receipt and quarantine
- Supplier and vehicle
- Tanker, drum or bag receipt
- Weight or volume received
- Sample drawn and tested
- Quarantine until approved
- Lot number and expiry
- Certificate of analysis on file
- Storage tank or warehouse location
- Rejected material returned
Tank, drum and warehouse stock
Stock sits in tanks, drums, IBCs and bags. Each container has a content, a lot and a location.
- Tank levels and dips
- Drum and IBC register
- Stock by lot and location
- Incompatible materials kept apart
- Flammable store limits
- Transfer between tanks
- Returnable container tracking
- Shelf life and retest alerts
- Stock count and variance
Batch planning and the batch record
- Batch number and size
- Formulation version used
- Reactor, blender or tank
- Materials charged with lot numbers
- Weighing or metering readings
- Steps with actual time and temperature
- Operator and supervisor
- In-process samples
- Yield against theoretical
- Deviations noted during the batch
- Batch closure
Reactor and process records
- Reactor charge and sequence
- Temperature and pressure readings
- Agitator speed
- Reaction time
- Distillation and recovery quantities
- Filtration and drying
- Process alarms noted
- Cleaning between batches
- Reactor occupancy
Blending and filling
- Blend from approved batches
- Drum, can, bottle and tanker filling
- Fill weight and count
- Label applied with batch number
- Pallet and case build
- Filling line changeover and cleaning
- Pack-size conversion from bulk
- Over-fill and loss
QC laboratory and batch release
A batch is held until the laboratory passes it. The lab’s result is the release.
- Batch sampled
- Tests assigned
- Results entered
- Compared with specification
- Released, reworked or rejected
- Certificate of analysis issued
- Test method and specification per product
- Viscosity, pH, density, solids and assay
- Retained sample register
- Out-of-specification investigation
- Rework by adjustment
- Instrument calibration due dates
- Certificate of analysis in the customer’s format
Hazardous material handling and safety data
- Safety data sheet library by version
- Hazard labelling by product and market
- Storage compatibility rules
- Flammable and toxic stock limits
- Spill and incident record
- Permit to work records
- Personal protective equipment issue
- Safety training record
- Waste manifest and disposal
The software gives structure and records, while your adviser provides the tax judgement. The system holds the records and the rules you give it, and the responsibility for meeting them stays with your safety team.
Effluent, waste and by-products
- Waste generated by batch
- Solvent recovery and reuse
- Effluent treatment plant readings
- Hazardous waste storage and disposal
- Waste contractor and manifest
- By-product sold or reused
- Waste cost per product
Lot and batch traceability
- Raw material lot to batch
- Batch to filled drums
- Drums to customer
- Customer complaint to batch and materials
- Recall list by batch
- Certificate and test results per lot
- Retained sample reference
Orders, dispatch and transport
- Customer orders and contract prices
- Stock allotted by batch
- Packing list and labelling
- Tanker and drum dispatch
- Vehicle and driver details
- Hazardous goods transport documents
- Delivery proof
- Returns and complaints
Costing and yield
- Material cost per batch
- Yield variance by product
- Solvent and utility consumption
- Labour and machine hours
- Cost per kilogram against price
- Raw material price movement
- Margin by product and customer
Maintenance and plant safety
- Reactor and pump maintenance schedule
- Pressure vessel inspection due
- Safety valve test dates
- Calibration of weighing and metering
- Breakdown history
- Shutdown planning
- Spares for pumps, seals and gaskets
Purchasing, invoicing and export
- Purchase requisition and order
- Supplier invoices
- Tax invoice in your tax rules
- Currency per customer
- Export documents and certificates of origin
- Customer price lists
- Outstanding by age
- Credit notes
One connected workflow, end to end.
Every stage below can sit in one system, so nobody re-enters what the last stage already captured.
- Raw material receipt
- Quarantine and release
- Formulation selected
- Batch planned
- Charging and reaction
- In-process sampling
- Blending and filling
- QC testing and release
- Storage
- Order and dispatch
- Invoice and collection
You do not have to replace everything at once.
Each phase is usable on its own, so the system earns its place before the next part is built.
- 1
Materials, formulations and stock
The material master, formulation versions, receipt and quarantine, and tank and drum stock.
- 2
Batches, QC and release
Batch records, reactor readings, laboratory tests, certificates of analysis and rework.
- 3
Safety, waste and traceability
Safety data library, storage rules, waste records and the trace from raw lot to customer.
- 4
Orders, costing and reports
Customer orders, hazardous goods dispatch, batch costing and views for the owner and the plant head.
How a build actually runs.
- 01
Follow a batch
We watch one batch from material receipt to a filled drum and note every record written along the way.
- 02
Agree the formulation record
Version, tolerance and approval are set before any batch screen is drawn.
- 03
Separate the roles
Operators, lab staff, store keepers and safety officers each see only the records they work with.
- 04
Build the batch and release first
The batch record and the QC release are the base that traceability grows from.
- 05
Run one product family
A single product family works on the new record while paper batch sheets continue.
- 06
Load stock by lot
Opening stock in tanks and drums is entered with lots and retest dates.
- 07
Add families and sites
More products, lab methods and plants follow when the first family is steady.
What you bring, and when.
The build moves at the speed of the answers. These are the things we ask for, in the order we ask.
- 01
Master lists and finished batch records
We read your material and product masters, current formulations, completed batch records and QC test sheets. Safety data sheets help. Design follows these papers.
- 02
A plant chemist and a QC analyst
The plant floor and the laboratory each need someone who knows the true routine. They put the draft through its paces. The plant head rules when production and QC disagree.
- 03
Test limits, recipe versions and release criteria
Batch and QC modules wait on test limits, recipe versions, quarantine rules and release criteria. Tank and drum inventories matter too. Nothing moves on until the current module has been reviewed.
- 04
Opening stock and instrument links
Stock by tank, drum and lot, open orders and approved vendors are brought across at go-live. Name the scales and laboratory instruments that should connect. The head of quality gives approval.
Systems we can put together for you.
- Material and product master systems
- Formulation and recipe version control
- Batch manufacturing records
- Reactor and process logs
- QC laboratory and release software
- Certificate of analysis generators
- Tank, drum and container stock systems
- Hazardous material and safety data libraries
- Waste and effluent records
- Lot and batch traceability tools
- Customer order and dispatch portals
- Batch costing and yield analysis
- Chemical stores and purchase systems
- Multi-plant chemical platforms
Questions owners ask before starting.
What is custom chemical manufacturing software?
It is a system fitted to one plant’s formulations, batches, hazards and customers, unlike an off-the-shelf factory package. Formulation control and batch release are usually where packages stop fitting.
How are formulations kept confidential?
Access is limited by role, so an operator sees quantities for a batch without seeing the full recipe.
Will it record laboratory results and issue certificates?
Yes. Test methods and limits are held per product, and a certificate of analysis can be printed in the layout a customer asks for.
Does it handle hazardous material rules?
It holds the safety data, storage classes and labelling rules you give it. Meeting the regulations remains the responsibility of your safety team.
How are tanks and drums tracked?
Tank levels, drums, IBCs and returnable containers are each held with their contents, lot and location.
What does a complaint trace back to?
It reaches the raw material lots, provided each batch records the lots it used. The trace then runs from the customer back to the supplier’s lot.
Will plant instruments connect to it?
Where a reactor controller, scale or meter exports readings, they can usually be brought in. This is reviewed against your equipment during design.
Is toll manufacturing covered?
Yes. Customer-owned materials and formulations can be kept apart from your own, with separate stock and batch records.
What if several plants share one system?
Every plant keeps separate batches and stock. Head office can still read all of them side by side.
How do we begin?
Share one formulation, a completed batch sheet and a laboratory report for the same batch. We then describe what would be built and in what order.
How we work with this trade.
Ready products for this work.
If one of these fits, it is cheaper and faster than building from scratch. We will say so.
Build a chemical plant system that keeps the formula and the batch together.
A customer complaint about a drum is answered by the batch record and the lab result. If they sit in different places, the answer is slow and uncertain.
Send one formulation, the matching batch sheet and its test report. The written reply explains how the three would be linked and which piece comes first.
Tell us how your chemical and specialty chemical manufacturers runs today.
We will tell you what can be digitised, what can be connected, what is worth automating, and what you should leave alone.
What happens after you share your requirements
- A senior engineer reads your answers. Nobody phones first.
- Within one business day you get a written note: what we understood, what we would start with, and the questions we still have.
- If it fits, a proposal follows with the order of work, what we need from you and what you receive at each step.
- No call is booked and nothing is paid until you have read the note. Your details stay with us.
Start with your requirements
Seven short steps that tell us what you need. A senior engineer reads them before anyone gets in touch.
Share your requirements