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GullySystem
Manufacturing · Software for plastic extrusion companies

Tie each die, screw speed and compound lot to the metres cut and bundled.

Pipe, profile and sheet lines turn pellets into metres, and the record that matters runs from compound lot through screw speed and melt pressure to the bundle tag. Each link is stored, so a complaint about one pipe length traces back to a resin lot, a die and a shift.

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At a glance

An extrusion line rarely stops. The die, haul-off and cutter are set once, and then metres pour through the sizing sleeve and spray tank for hours while nobody touches a dial. Thin walls pile up as scrap before anyone looks.

Management software for plastic extruders writes screw speed, zone temperatures, compound lot and metres cut next to the order, so a query months later opens one record instead of a clipboard. Send us your die list, your compound grades and the cut lengths you run, and the record is shaped to match, from the first quote through to the bundle tag.

How the work runs today

Enquiries name a pipe diameter and pressure class, a profile section or a sheet gauge, plus a cut length and a quantity in metres. Quotes start from kilograms per metre, line output in kilograms per hour, compound price and the cost of a masterbatch change. The die waits in the tool store or must be machined. A new die means a trial.

At the line, the operator heats the barrel zones and feeds compound from the hopper through the screen pack and breaker plate. Melt leaves the die, passes the vacuum calibrator and spray tank, and is gripped by the haul-off before the saw cuts it. Samples are cut at set intervals and measured with a pin gauge and an ultrasonic wall gauge against the limits drawn by the buyer. Purge is weighed. Bundles are strapped, tagged and counted.

Where it breaks

What goes wrong for plastic extrusion companies without a proper system.

Start-up scrap is never costed

Each colour change and die change burns compound before the first good metre leaves the saw. Purge, die-lip drool and trimmed ends go to the regrind bin unweighed. So the yield you quoted and the yield you achieved drift apart, and the loss slides quietly into the next job’s price.

Dimensions are measured and then lost

Wall thickness, outside diameter and ovality are read at the tank and noted on a clipboard, and the sheet is filed by date, not by order. When a buyer queries one bundle three weeks later, nobody can find the readings taken at that hour.

Compound lots blend unseen

Virgin PVC-U or polyethylene, stabiliser, titanium dioxide, masterbatch and reground pipe ends all drop into one hopper. The recipe behind a given metre lives in the operator’s memory, a poor place to look when a buyer asks about pipe delivered last quarter.

Dies are not tracked

A die needs cleaning, mandrel checks and lip polishing after a run, but without a count of metres through it, a worn land leaves die lines and uneven walls. Nobody notices until a buyer rejects a bundle at the gate.

Cut-length orders mix up on the floor

Five customers may want one profile in five lengths. Tags are written by hand with a marker. A bundle of three metre lengths reaches the truck meant for a six metre order.

What the software does

What we would build for plastic extrusion companies.

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

Profile and pipe register

Store each pipe or profile with its die number, nominal diameter, SDR (the ratio of diameter to wall), tolerance band and ordered cut lengths. A repeat order starts from known figures.

Line run log

Capture screw speed, barrel zone temperatures, melt pressure, haul-off speed, kilograms per hour and metres produced for each run on each line, with the operator’s name on the shift.

Compound and additive stock

Track compound lots, titanium dioxide, stabiliser, colour masterbatch and regrind, and note the recipe each run drew from the hopper, so a complaint traces back to a bag.

Dimensional checks

Record wall, outside diameter, ovality and surface checks taken during the run, and hold bundles that fall outside the buyer’s limits until someone decides what to do.

Die and tooling record

Log metres through each die, with cleaning, lip polishing, mandrel repair and screen pack changes, and warn the line supervisor when a die is due for the tool room.

Bundle tagging and dispatch

Print bundle tags with section, cut length, compound lot and order, then issue a delivery note from the bundle count, so the truck leaves with the right lengths.

Before you talk to a supplier

A requirements checklist for plastic extrusion companies.

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 product

A product already built for plastic extrusion companies.

It is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then.

Plastic Extrusion Company Management Software

Section designs, line run logs, compound and regrind stock, die records, dimensional checks and bundle dispatch for plastic extrusion companies.

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Solutions inside

The business modules plastic extrusion companies use most.

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

Services

The services behind it.

Business Process Automation

Approvals, reminders, follow-ups and reports that run on their own instead of on someone remembering.

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IoT and Edge Computing

Machines, meters and sensors feeding the same system your office uses, even when the network drops.

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ERP, CRM and Business Software Implementation

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

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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.

Our work

Software we have built and run.

We only name clients whose work is published. These are systems our team designed, built and supports.

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Common questions

Questions plastic extrusion companies ask before they call.

Is it suitable for pipe, profile and sheet lines?

Yes. Pipe carries wall and outside diameter checks, profile carries section and straightness, and sheet carries gauge and width. A run links to whichever applies, so each product gets its own sheet.

Can it record scrap by cause?

Yes. Start-up scrap, purge, trim and saw-end offcuts are each weighed and logged against the run. A colour change then shows its real cost, and the next quote can use it.

Does it cope with co-extrusion?

Yes. A run can list a main extruder and a co-extruder with the compound each feeds. The skin layer and core layer lots are recorded together.

What decides the cost?

The number of lines, users and test fields decides the cost. We demo one of your own sections first and send the written offer afterwards.

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.

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.

  • No obligation
  • A reply within one business day
  • Your details stay private

Start with your requirements

Seven short steps that tell us what you need. An engineer reads them before getting in touch.

Share your requirements