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GullySystem
Manufacturing · Software for yarn manufacturers

Trace every cone back to its bale lot, mixing plan and ring frame.

Spinning mills turn bales of cotton, polyester or blends into cones of a stated count and twist. Waste, yield and test readings are usually kept in separate registers. The yarn product holds bale lots, mixing plans, frame runs, lab results and packing on one lot record.

At a glance

A spinning mill turns fibre into yarn. Cotton or polyester bales arrive with a lot number and a fibre test, and they leave as cones in a given count, twist and package weight. Every step changes the quantity, so the mill keeps a running account of waste.

Orders are taken by count and quality. One buyer wants a combed count, another wants polyester blended with viscose, and both set tolerances for evenness, neps and strength. The mill must show a test report for each lot it sends. Buyers ask for it.

How the work runs today

The mixing room lays down bales by lot to a mixing plan. The blow room, cards and drawing frames follow, and each department weighs its own production and waste. Supervisors write sliver weights and hank readings on a sheet beside the machine, and the clerk copies the figures into a daily production register that the manager reads the next morning.

Roving goes to the ring frames, where spindle breaks, count variation and doffing set the pace of the day. Winding turns bobbins into cones, clears the faults and fixes the package weight. The lab tests evenness, strength and imperfections on samples drawn at the frame and at the winder.

Finished cones are packed by bag or carton, with lot, count and net weight marked on the label. A despatch clerk checks the packing list against the buyer’s order. The test report goes out with the invoice. Nothing leaves unlabelled.

Where it breaks

What goes wrong for yarn manufacturers without a proper system.

Bale lots blend without a trace

Bales from several lots are laid down together in the mixing room. When a buyer reports streaky fabric, the mill cannot say which bales fed that count.

Waste is weighed in pieces

Blow room droppings, card strips, comber noil and ring frame waste are weighed in different places. Yield is a monthly sum. Often it is not done.

Test readings stay in the lab

Count, evenness, thin and thick places, neps and strength are tested on samples. The result sits on its own sheet and does not travel with the lot sent to the buyer.

Stoppages hide in the shift book

A breakdown on a ring frame or a winder is written in a register by the supervisor. The supervisor knows a frame was down, but the spindle hours it cost appear only when the register pages are totalled at month end. Meanwhile the fault repeats.

Count changes reach the floor late

A buyer rings to change the count or bring the date forward. The planner moves the frames, but the mixing plan and the packing instruction still show the old order.

What the software does

What we would build for yarn manufacturers.

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

Bale intake and mixing plan

Record each bale lot with its fibre test, then lay the lots into a mixing plan by count so every cone traces to its bales.

Department production and waste

Capture production and waste from blow room to winding by shift, with the yield from fibre to cone shown for each lot.

Frame allocation by count

Assign counts to ring frames, note spindle speed, twist and doffing, and see which frames are running which order.

Lab readings by lot

Store count, evenness, imperfection and strength readings against the lot and print the report that goes out with the cones.

Machine stoppage log

Log breaks and maintenance by frame and winder, with a cause code and the spindle hours lost.

Packing, labels and despatch

Pack cones to a bag or carton weight, print the lot label and match the packing list to the buyer’s order.

Before you talk to a supplier

A requirements checklist for yarn 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 product

A product already built for yarn manufacturers.

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

Yarn Manufacturer Management Software

Bale lots, mixing plans, department waste, ring frame allocation, lab readings, machine stoppages and cone packing for spinning mills.

See the product
Solutions inside

The business modules yarn manufacturers use most.

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

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.

Common questions

Questions yarn manufacturers ask before they call.

Does it run the spinning machines?

No. Machines keep their own controls. This system records what they produce, what they waste and how long they stood, from entries at the frame or from counters your supplier can connect.

Can we keep one mixing plan for several counts?

Yes. A plan lists the bale lots and their share, and each count that uses it points back to that plan. A change to the plan is dated and shown on later lots.

We spin both carded and combed yarn. Is that handled?

Yes. Comber noil and card strips are separate waste heads, and the yield for each route is reported on its own. Your department list is entered as the mill runs.

How do mills usually start?

With the live orders, the count list and the open bale stock. A trial on one department comes before the full mill, and the lab chooses which readings it wants captured.

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