Run formulas, mixing batches, laboratory readings and filling from one batch record.
Manage product formulas, batch cards, surfactant and packing material lots, pH and viscosity readings, filling runs, retained samples and distributor dispatch for cleaning product production. Each tank is recorded with the drum lots that went into it, the adjustments made at the agitator and the readings that released it, and filled cartons carry the batch code. A complaint from a shop leads back to one tank.
- Formulas, limits and pack sizes recorded as your laboratory writes them
- Unfilled orders, raw material lots and cap and trigger pack stock brought across
- Later changes to formulas and batch fields are made by GullySystem staff on request, without a new project.
Cleaning Product Manufacturer Management Software links formulas, batch cards, chemical drum lots, laboratory readings, filling lines and dispatch. Every tank is recorded with the lots used, the thickener or water added after sampling, the filled carton count and the readings that released it. A complaint traces to one batch.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Formula and plan
Each product has a formula with limits for pH, viscosity and density, and the plan converts distributor orders into tank batches by size.
- 2
Raw material issue
Chemicals are issued to the tank by lot and weight. Expiry is checked before a drum leaves the store.
- 3
Blending
The operator adds ingredients in the order on the card, from caustic soda flakes to perfume last, and notes each adjustment and the mixing time on the agitator.
- 4
Laboratory release
The laboratory checks readings against limits. A batch outside them is held or corrected, and the decision is recorded with the chemist’s name and the time the sample was drawn from the tank.
- 5
Filling and packing
Containers are filled, capped, coded and cartoned, and counts, rejects and purge loss are logged against the batch before the tank is closed. Pallets are built after that.
- 6
Dispatch and traceability
Cartons leave with the batch code on the delivery note, so a complaint or recall lists every customer that holds the batch, the quantities each received and the dispatch dates.
What is inside.
Every module can be switched on, left out or changed to match how your team already works.
The business modules it is built from.
Each one is also available on its own, or inside a system built for you.
- Bill of Materials
Each product’s ingredients, quantity per tank and order of addition are held as a recipe that every batch card is built from.
- Production Planning
Distributor and institutional orders turn into tank batches by product and bottle size, with chemical and packing needs shown ahead of the run.
- Batch and Serial Tracking
Chemicals are received and issued by lot with expiry, so each tank records which surfactant and perfume drum lots went into it.
- Work Order Management
Every tank opens as a work order that captures quantities, adjustments, mixing time and the operator, and closes only when the filling count is entered.
- Quality Control
pH, viscosity and density are recorded against the product’s limits, and a tank outside them stays held until a decision is entered.
- Stock Tracking and Alerts
Bottles, caps, pumps and labels are counted by size, and an alert appears before a filling run is short of any item.
- Goods Receipt (GRN)
Drums and bags are booked on arrival with lot, weight and expiry, so only booked material can be issued to a tank.
- Invoice Management
Invoices are raised from dispatched cartons with the batch code, and each distributor’s balance is shown with the oldest dues first.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For blending operators
See the batch card for the tank, record weights and adjustments, and call the laboratory when mixing ends. The card shows the next ingredient and its drum lot, in the order the formula demands.
For the laboratory
Record pH and viscosity readings against limits, release or hold a tank, and log retained samples with their shelf place. Held tanks stay locked for filling until the decision is entered.
For the chemical store
Receive drums by lot and expiry, issue them to batches, and see which lots are near their dates before they reach the blending hall.
For filling supervisors
Log filled counts, rejects and purge loss, and see the caps, pumps and labels needed for the next run before the line is changed over.
For owners and sales
Read batches released, stock of finished cartons, distributor dues and complaints by batch, so the products that draw the most complaints show first on the owner’s screen.
The numbers the owner asks for.
- Batch yield against tank volume
- Thickener and water additions at the tank, by product
- Surfactant, perfume and preservative lots by expiry date
- Viscosity and pH readings outside limits
- Filling rejects and purge loss by line
- Customers holding a given batch
- Retained samples due for disposal
Who this is built for.
- Makers of floor, glass and toilet cleaners
- Dishwash liquid and gel manufacturers
- Detergent powder blenders and packers
- Disinfectant and sanitiser producers
- Plants that fill institutional cleaning chemicals in drums and jerry cans
When it is not the right choice.
- A small unit stirring a few litres in a bucket for neighbouring shops can get by with a notebook and pH paper.
- Makers of cosmetic or personal care products will find Herbal Product Manufacturing Software closer.
Adapted to your business before it goes live.
You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.
Works alongside
- SMS
- Barcode and label printers
- Accounting export
Questions owners ask before a demo.
Can operators change a formula at the tank?
They can record an adjustment, but not edit the formula. The change is saved with the person and a reason, and the laboratory sees it before the tank is released to filling.
How are liquid and powder products handled?
Liquids are batched by tank volume and powders by ribbon blender load. Each product sets its own unit, so a dishwash gel and a washing powder both sit in one register without any special handling.
Can we hold a tank until the laboratory approves?
Yes. A batch stays at held status until readings are entered within the limits, and filling cannot draw from a held tank. The operator at the filling line sees the lock.
How do expiry dates work for chemicals?
Each lot carries its expiry. The store sees lots close to the date, and the issue screen warns before an old drum of perfume or preservative is drawn.
Can a recall list be produced?
Yes. One search on the batch code lists the customers, the quantities and the dispatch dates, ready for contact. The list prints from the screen.
How is filling loss reconciled?
Containers filled, rejects and purge loss are compared with the tank volume, and the gap shows as batch yield by line. A leaking valve or a short fill stands out at once on the report.
Are retained samples tracked?
Yes. Each sample is logged with its shelf location and disposal date. The laboratory sees which bottles are due for disposal and clears them in one pass.
Can recipes and stock be moved in?
Yes. We import formulas, chemical lots, packing stock and open orders from your spreadsheets, and the laboratory proves the formulas on a test batch before they are used.
Does it certify our products?
No. Testing and release rules come from your own laboratory and regulatory staff, who review them during implementation. The software records the readings and the decision.
Who supports it after go-live?
GullySystem staff handle changes to formulas, fields and layouts when asked. Larger changes are quoted before the work begins.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Cleaning Product Manufacturer Management Software with your own data.
Tell us how you run things today. We’ll show you the parts that matter to you and say plainly what would need changing.
- No obligation
- A reply within one business day
- Your details stay private
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