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GullySystem
Manufacturing · Software for chemical manufacturers

Link formulations, batches, QC results and dispatch by batch number.

Specialty chemical, rubber and plastic makers often hold formulations in Excel, batch sheets on paper and QC results in a register. Batch records, QC and dispatch are built around your own formulations and plant, with versions kept and access limited. A batch number then shows what went into the kettle and which customer received the drums.

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At a glance

You make specialty chemicals, adhesives, coatings, cleaning products, rubber parts or plastic mouldings, and most of it goes to industrial buyers who audit their suppliers. What they value is the same viscosity, hardness and colour, batch after batch.

That consistency lives in formulations, batch sheets and QC results. Every customer complaint sends someone digging through all three.

How the work runs today

Raw material arrives with a supplier certificate of analysis (COA). QC draws a sample, checks it against the incoming specification and approves the lot. The storekeeper books it to a bin, and production issues material against a batch sheet carrying the formulation, the kettle charges and the process times.

Each finished batch is tested for the properties the customer cares about, such as viscosity, pH, solids or hardness, and a COA is prepared and checked against the customer’s specification. A retained sample goes to the shelf. Material is filled into drums, carboys, IBC totes or bags, labelled and sent with the safety data sheet. Rubber and plastic units also track moulds, cycle times and rejection by shift, and send parts out for plating, printing or compounding on a dispatch note.

Dispatch needs four papers together. They are the tax invoice, the delivery note, the batch documents and any transport document the route requires, and a hazardous load adds its UN number and class to the label. When a complaint arrives, the batch is traced back to the lots that made it. That is the moment the records are needed.

Where it breaks

What goes wrong for chemical manufacturers without a proper system.

Tracing a batch is slow

The batch sheet, QC register and raw material inward book are kept separately, so a complaint about a sticky adhesive means three books and one tired storekeeper. The customer waits while they are matched.

Formulations sit in one person’s Excel

Recipe changes are not versioned, so it is unclear which version produced a given batch of resin or compound. Rework decisions then rest on someone’s recollection of what the charge weights were.

Rejection and yield are not measured

Off-spec batches are reworked, re-blended or let down into a lower grade without a record, so real yield is not known. The losses in the kettle and the filling line stay hidden.

Job work sent out is not reconciled

Material leaves for a plater, printer or compounder on a dispatch note. What returns, and what was lost as sludge, flash or spillage on the way, is settled from memory months later.

Returnable drums go missing

Returnable drums and carboys are tracked on paper, sometimes. Many do not return, and each one is a deposit sitting in a customer’s yard. Nobody counts them until the audit.

What the software does

What we would build for chemical manufacturers.

Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.

Formulation master with versions

Keep recipes with their version history, open only to the people you authorise by name. This layer is built beside the production software, and every batch links to the version that made it.

Batch manufacturing record

Record material issued, process steps, operator and yield for every batch at the plant, while the batch is still in the reactor or on the mill.

QC, COA and retained samples

Record test results for raw material and finished batches against the customer’s specification, note the shelf where the retained sample is kept, and generate the COA from those readings. Inspection and rejection come from the production software, and the COA is added during implementation.

Lot traceability

Trace any finished batch back to its raw material lots and forward to the customers who received it, through a lot link added over the work orders at set-up.

Job work sent out

Send material to a plating, printing or compounding vendor against a dispatch note, and reconcile what comes back against what went, including sludge and flash.

Returnable container register

Track drums and carboys sent out and returned, customer by customer, with the count held at each yard. The register is a custom addition.

Mould and rejection log

For rubber and plastic units, rejection by reason, such as flash, short shot or under-cure, is counted on the job cards. Cycles per mould and maintenance due are added as a custom register.

Before you talk to a supplier

A requirements checklist for chemical manufacturers.

What to cover, which reports to ask for and what to put to every vendor, ready to print or save as a PDF.

Open the checklist
Ready products

Ready products we start from for chemical manufacturers.

Each one is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then. You are not paying to build the basics again.

Manufacturing Production Management Software

Work orders, multi-level bill of materials, job cards by stage, bar and sheet issue, rejection reasons, subcontracted job work, dispatch and tax billing for manufacturers.

Learn more

IoT Monitoring Dashboard

Live values, thresholds and alerts, downtime and run hours, and the history behind every reading from your machines, meters and sensors.

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More products

Other products in the same sector as chemical manufacturers.

Solutions inside

The business modules chemical manufacturers use most.

Each one is also available on its own, or inside a system built for you.

All solutions by area

AI by department

Where AI can help chemical manufacturers.

Each one reads records you already keep, and a person approves every decision.

Services

The services behind it.

ERP, CRM and Business Software Implementation

One record of stock, orders, customers and accounts, set up so your team opens it every day.

Learn more

Custom Software and Product Engineering

Software built around how your business actually runs, when nothing off the shelf fits without workarounds.

Learn more

Data Engineering and Business Intelligence

Dashboards that answer the owner’s Monday questions without anyone building an Excel sheet first.

Learn more

Cybersecurity and Application Security

Logins, roles, backups and data exposure checked, so a staff exit or a lost phone is not a crisis.

Learn more

All our other services

Guides

Written for chemical manufacturers.

Practical notes on running the business, not product marketing.

How to Set Up Batch Traceability in a Chemical or Polymer Plant

Link raw material lots, formulation versions, QC results, COAs and dispatches to one batch number, so a complaint can be traced back without a hunt.

Learn more
How it works

How the work runs from Bengaluru for your city.

  1. 1

    The audit, by call

    A screen-share and a look at the sheets, accounting reports and WhatsApp groups your team uses. No travel needed.

  2. 2

    A written proposal

    Scope, what we build first and the cost, agreed in writing before anything starts.

  3. 3

    Build in short rounds

    Working screens shared every few weeks. Your team tests them from your own office.

  4. 4

    Go-live, in person when it helps

    For data migration and training we can come to your city. Travel is agreed in advance.

  5. 5

    Support online

    Fixes, changes and hosting handled remotely by the same team that built it.

Published case studies

The work we have published.

We only name clients whose work is published. None of them is in this trade; they show how the team works, not that it has built for this trade.

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Registration, fee collection, routing and finance write to the same records, closing the gap between journeys run and fees collected.

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Loan proposals, recoveries and commissions sit on one record, with a person attached to every state change, so a business handling a bank’s money can show where each rupee went.

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Common questions

Questions chemical manufacturers ask before they call.

Will our accounts system still handle tax and accounts?

Yes. Your accounts stay in your finance package, and batch, QC and formulation detail stays in the new system. No link is built in. An export file is an extra, quoted once the ledger heads are agreed.

Will this make us compliant with pollution or safety rules?

No. Compliance comes from how the plant is run and what your licences require. The software provides a record of batches, tests and dispatches that can be produced when an auditor or customer asks.

Should we buy a process manufacturing ERP instead?

It depends on size. A larger plant may fit a ready process ERP. For the rubber and plastic side, work orders, bill of materials and job work sit in our manufacturing production software. Formulation versions, batch records and COA are built beside it.

How are our formulations protected?

They sit in the formulation layer built for you. Only named people open them, every view is logged, and the floor batch sheet can show charge quantities without the recipe.

How is a chemical plant system quoted?

Formulations and versions to load, plants and warehouses involved, and the users in lab and stores matter most. Returnable drum tracking and job work are separate modules. Reading the scope comes first, and each module is then given a figure so any can be left out.

What must a chemical maker have ready before the work starts?

Bring formulation sheets as they exist today, a filled batch record, QC registers with certificates of analysis, and a dispatch note. Include the job work challans. A plant head and a QC chemist then spend time answering questions and testing the screens.

Who keeps the formulations and batch history if we leave?

Your company does, along with the code. Formulations stay access-controlled, and every batch, QC and dispatch record leaves in plain files. The team that wrote the software continues to support it. Hosting is with GullySystem, or elsewhere if you ask.

What happens after I share my requirements?

An engineer reads what you send and replies within one business day. We then look at the software, spreadsheets and WhatsApp groups your business runs on today and write down what works, what slows your team down and what is missing. A demo login, a screen-share or a few screenshots are enough. You get a short written summary ordered by priority, with no obligation to hire us afterwards.

How much will the software cost?

We don’t publish a price, because it depends on what the system has to do. That first review settles the scope, and the cost goes into a written proposal before any work starts.

In Bengaluru

Bengaluru areas with many chemical manufacturers.

Across India

Cities where chemical manufacturers are common.

Related

Related industries.

Category

Part of a wider group.

Talk to us

Tell us how your business runs today.

A few lines on your spreadsheets, software and WhatsApp groups is enough. We reply the same working day.

What happens after you share your requirements

  1. A senior engineer reads your answers. Nobody phones first.
  2. Within one business day you get a written note: what we understood, what we would start with, and the questions we still have.
  3. If it fits, a proposal follows with the order of work, what we need from you and what you receive at each step.
  4. 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