Build a system around your compounds, your moulds and your cure cycles.
A rubber plant starts with a recipe. Polymers, fillers, oils and curatives are weighed, mixed and sheeted, then moulded, extruded or wound into the part the customer ordered.
The compound is the first risk. A mix that is a little off gives a part that cures wrong, and the fault shows only after moulding. The batch number is the thread that ties it back.
Software built by GullySystem for such a plant would hold the compound, the mould, the cure and the inspection record together. A returned part could then be traced to its mix.
Plants this can be built for.
A moulding shop presses parts in cavities. A hose plant extrudes and cures lengths. A belt plant builds plies. The process differs in each, and so do the records that matter.
- Rubber moulding companies
- Rubber gasket manufacturers
- Seal and O-ring manufacturers
- Rubber hose manufacturers
- Silicone component manufacturers
- Conveyor belt manufacturers
- Industrial rubber parts manufacturers
- Rubber to metal bonded part makers
- Rubber sheet and roll producers
- Rubber extrusion companies
- Tyre retreading plants
- Rubber roller and lining makers
- Anti-vibration mount manufacturers
- Rubber compounders and mixers
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.
Part master and customer drawings
Every part has a drawing, a hardness, a compound and a tolerance class.
- Part number and revision
- Customer drawing and tolerance
- Compound specification
- Hardness and colour
- Mould and cavity count
- Flash and trim standard
- Packing instruction
- Approved sample record
Compound recipes and formulation
Technical teams own the recipes. Changes to a recipe are recorded and approved.
- Recipe by compound code
- Polymer, filler and oil quantities
- Curative and accelerator quantities
- Recipe revision and approval
- Customer-approved compound lock
- Raw material alternates allowed
- Cost per kilogram of compound
- Recipes by end product
Recipes are valuable to the plant. Access is limited by role, so operators see the weighing sheet and not the full formulation.
Raw material stores
- Rubber bales by grade and lot
- Carbon black and fillers
- Oils, curatives and chemicals
- Metal inserts and bonding agents
- Shelf life and expiry
- Supplier test certificates
- Storage conditions for sensitive items
- First expiry, first out issue
Mixing and batch records
Mixing teams weigh and mix each batch to the recipe and record what actually went in.
- Weighing
- Internal mixer
- Mill sheeting
- Cooling and storage
- Rheometer sample
- Release for moulding
- Batch number per mix
- Material lots used
- Weights against recipe
- Mixing time and temperature
- Operator and shift
- Batch hold until the test passes
Compound testing and release
- Cure curve from the rheometer
- Viscosity reading
- Specific gravity
- Hardness of a cured sample
- Tensile and elongation
- Compression set
- Pass, hold or reject decision
- Test result linked to the batch
Production planning and work orders
- Plan from orders and stock
- Mould and press matched
- Compound batch allocated
- Work order per part and lot
- Shift-wise output entry
- Delayed orders flagged
- Rush orders inserted
- Press load for the week
Mould and tool management
A mould is an expensive asset, and its condition decides the quality of every part.
- Mould register by part
- Cavity count and cavity numbers
- Cycles run since last cleaning
- Cleaning and repair history
- Mould in the press, store or toolroom
- Customer-owned mould flagged
- Spare mould inserts
- Mould life against plan
Moulding, extrusion and curing
Press operators record the settings and output for each run.
- Press, mould and compound used
- Cure temperature and time
- Pressure setting
- Preform weight
- Shots and parts produced
- Extrusion line speed and die
- Autoclave or oven cycle
- Operator and shift
Cure settings come from the approved process sheet for each part. A run outside those settings is flagged to the supervisor, who decides what happens to it.
Trimming, deflashing and post-cure
- Trimming method per part
- Cryogenic deflashing batches
- Post-cure oven loads
- Quantity in and out
- Rework count
- Surface treatment or coating
- Semi-finished stock by stage
Inspection and quality checks
- First piece approval
- Dimension checks with gauges
- Visual defect classification
- Hardness check on the part
- Leak or pressure test for hoses and seals
- Bond strength for metal-bonded parts
- Sampling plan by lot
- Reject reasons recorded
Lot traceability
A returned part is traced backward through the press run, the compound batch and the raw materials.
- Finished lot number
- Linked work order and press
- Compound batch used
- Raw material lots in the batch
- Mould and cavity of origin
- Customer shipment of the lot
- Search by any link in the chain
Wastage and scrap
- Scrap by stage and cause
- Flash and runner weight
- Rejected compound batches
- Regrind and reuse where allowed
- Scrap sold by weight
- Yield per compound batch
- Wastage against the cost sheet
Costing and quotation
- Compound cost per kilogram
- Part weight and material cost
- Press time and labour cost
- Mould cost recovery
- Trimming and packing cost
- Quote revision
- Cost of a part against its quote
Packing, dispatch and billing
- Packing by quantity and lot
- Label with part and lot code
- Delivery note and tax invoice
- Call-off schedule by customer
- Transport and vehicle details
- Credit and outstanding by customer
- Currency per customer
- Export documents where needed
Customer complaints and returns
- Complaint with part and lot
- Photographs and failed samples
- Retained sample comparison
- Cause traced to compound or press
- Corrective action with owner
- Credit note or replacement
- Repeat complaints by part
Who logs in, and what they see
- Owner
- Technical manager
- Mixing supervisor
- Press supervisors
- Toolroom team
- Quality team
- Stores team
- Planning team
- Dispatch team
- Accounts team
One connected workflow, end to end.
Every stage below can sit in one system, so nobody re-enters what the last stage already captured.
- Order
- Compound allocation
- Raw material issue
- Mixing
- Compound testing
- Moulding or extrusion
- Curing
- Trimming
- Inspection
- Packing
- Dispatch
- Invoice
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
Parts, recipes and raw material
The part master, compound recipes, raw material stores and expiry control, with role-limited access to formulations.
- 2
Mixing and testing
Batch records, weights against recipe, rheometer and hardness results, and a hold-and-release step before moulding.
- 3
Moulds, presses and inspection
Mould register, press settings, cure records, trimming, inspection and lot traceability back to each compound batch.
- 4
Dispatch and cost
Packing, call-off schedules, invoices, complaints and the cost reports that compare each part with its quote.
How a build actually runs.
- 01
Follow one batch
We follow a compound from the weighing room to a finished part in a customer’s carton, and list every record written on the way.
- 02
Separate the recipe from the weighing sheet
We agree with the technical head who may see a formulation and who may only see weights.
- 03
Design for the mixing room and the press
Screens are built for people with gloves, heat and noise around them, with large entries and few fields.
- 04
Start with batch and lot records
Mixing and lot traceability come first, since a complaint months later depends on what was recorded on the day.
- 05
Test with a quiet product line
One product family runs on the system beside the paper log. Each week ends with a short meeting where any mismatch between the screen and the log is traced to its cause.
- 06
Extend to every press
Other lines, moulds and customers follow, with costing and wastage reports added at the end.
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
Compound recipes, mixing logs and drawings
Provide a compound recipe sheet, a mixing batch record, a part drawing and a cure record. Inspection formats help. Photographs of the registers are enough.
- 02
Mixing supervisor, moulding lead and inspector
The mixing supervisor, a moulding lead and the inspector try early screens. A recipe change may clash with a customer approval. The technical head decides.
- 03
Cure settings, scrap limits and compound release
Cure time and temperature per part, scrap allowance and who may release a compound batch call for decisions. Batch records depend on them. Shop staff check what is demonstrated.
- 04
Raw material, moulds and open orders
Raw material stock, the mould register, pending orders and customer dues are brought in. Login to your accounting package is sorted out. The technical head approves.
Systems we can put together for you.
- Rubber moulding plant management
- Compound recipe and batch systems
- Mixing room batch records
- Mould register and life tracking
- Press and cure cycle logging
- Lot traceability to raw material
- Gasket and seal production tracking
- Hose and belt production records
- Inspection and test result systems
- Scrap and yield analysis
- Costing and quotation tools
- Call-off and dispatch management
- Customer complaint tracking
- Management dashboards
Questions owners ask before starting.
What does custom rubber plant software change?
It ties a finished part back to its mould, its press run, its compound batch and its raw materials. A complaint then has a trail to follow.
Can recipes be kept private from operators?
Yes. Operators see a weighing sheet with quantities for the batch, while the full formulation stays with the roles you name.
Where are compound test results kept?
Against the batch. Cure curves, hardness, tensile and other results are stored there, and a batch can be held until they are entered.
Can it track mould life?
Yes. Cycles are counted per mould, and cleaning or repair is flagged when the count reaches the limit you set.
Will hose, belt and extrusion plants be covered?
Yes, with different stages. Hose and belt plants track lengths and plies, and moulding plants track cavities and shots.
Can it trace a returned part to its mix?
Yes, where lot codes are recorded at packing. The search runs from the part back to the batch and the raw materials.
Will presses and mixers send it readings?
Sometimes. That depends on the machine controls. Otherwise operators enter the values and the system checks them against the process sheet.
Can metal-bonded parts be handled?
Yes. Insert lots, bonding agent batches and bond strength tests are linked to the part lot.
Would a ready product work for us?
Often. Our rubber moulding and gasket software covers common records, and a custom build suits plants with particular mixing or testing steps.
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 system that finds the batch behind every part.
Rubber faults often show late. The part looks fine, ships, and fails in service. What saves the account is knowing which mix it came from.
Show us a batch card, a press log and a customer complaint. We will show where the chain breaks, and what our ready rubber products already record.
Tell us how your rubber products manufacturing companies 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