One system for film structures, print cylinders, laminating runs and seal tests.
Film structures, reel stock, ink and adhesive lots, gravure cylinders, laminating runs, slitting, pouch making, peel and seal tests and invoices share one record. A PET and polyethylene laminate roll opens to its reels, adhesive batch and cylinder set. Estimators, press minders, laminator crews, lab testers and dispatch clerks read that roll card, from the brand’s first enquiry for a stand-up pouch to the label on the pallet.
- Layer lists typed the way each brand writes them, such as PET 12 over PE 60
- Customer list, cylinder register and open reel counts copied across before the first press run
- Press settings and test limits changed afterwards by our team when you ask
Converters of rollstock and pouches keep structures, film reels, print jobs, laminating runs and pouch lines in Flexible Packaging Manufacturer Management Software, which GullySystem configures to their plant. Every laminate roll links its outer film, sealant film and adhesive lot to the bond and seal tests taken on it. Core sizes follow the customer’s filling line.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Enquiry and structure
A brand sends the pack size, layer structure, print design and order quantity for a stand-up pouch or lidding film, and the estimator prices film weight, ink coverage and press time. Nothing is promised yet.
- 2
Artwork and cylinders
The brand approves artwork, and the print room confirms that the gravure cylinders or flexo sleeves already exist or must be engraved first. Engraving is booked as its own step.
- 3
Printing
The press prints the web, and each run notes the film reel, the ink lots, the viscosity readings and the metres produced. Scrap is weighed at the rewind.
- 4
Laminating and curing
Printed film is bonded to the inner layers with solventless or solvent-based adhesive, then rested in the curing room for the period set for that structure. The roll stays blocked until then.
- 5
Slitting and pouch making
Rolls are slit to width on the slitter rewinder and wound on cores, or converted into three-side seal pouches, stand-up pouches and sachets on the bag line. Every splice is marked.
- 6
Testing and dispatch
Samples go to the lab for bond and seal tests, rolls are labelled with core, length and splice count, and the packing list travels with the load. The invoice follows the delivery.
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.
- Quote & Proposal Management
Prices are built from film weight, ink coverage and press hours, and a reorder shows the earlier quote beside the revised one.
- Goods Receipt (GRN)
Each polyester, polypropylene or polyethylene reel is booked on arrival with micron, width and supplier lot before it is issued to the press.
- Batch and Serial Tracking
Ink batches and adhesive lots are linked to the laminate rolls that used them, so a complaint points back to one lot and one drum.
- Production Planning
Print jobs are sequenced by colour count and web width, and the laminator queue holds each roll until its cure period ends.
- Quality Control
Bond strength, seal strength, friction and residual solvent are entered against the roll, and a failing lot is held back from dispatch.
- Fixed Asset Register
Every gravure cylinder and flexo plate is listed with metres printed, re-chroming history and its storage position in the rack.
- Barcodes and Labels
Roll labels print core size, length and splice count in the customer’s layout, matching the packing list on the pallet.
- Work Order Management
A slitting or pouch job lists its source roll, widths and counts, and the crew closes it with waste and rejects recorded.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For owners
See reels in stock, rolls curing, cylinder life, tests outstanding and balances by brand without walking to the press floor.
For estimators and sales
Quote structures from stored layers and cylinder status, and reopen an earlier price when a brand returns with a revised pack size.
For press and laminator crews
Read the queue, the reels and inks to load and the settings to use for each job. Log metres printed and scrap at the rewind.
For quality staff
Enter bond, seal and solvent results, then decide whether a roll is released or held. The reasoning stays on the roll card.
For stores and dispatch
Issue film and ink to runs, label rolls with cores and lengths, and prepare the packing list from the pallet scan.
The numbers the owner asks for.
- Rolls by stage with curing dates and slitter readiness
- Film and ink consumed against metres delivered
- Edge trim and web waste by press, laminator and slitter
- Bond and seal results per roll with pass or hold status
- Gravure cylinders and flexo plates ranked by metres printed
- Pouch rejects by bag line, shift and film lot
- Brand invoices still open, longest overdue listed first
Who this is built for.
- Converters that print and laminate film for snack, confectionery and frozen food brands
- Pouch makers supplying stand-up, spouted and zipper packs
- Makers of rollstock for form-fill-seal and flow-wrap filling lines
- Plants running gravure and flexo presses side by side
- Companies whose brands ask for bond, seal and migration test records
When it is not the right choice.
- A shop that heat-seals a few plain bags by hand can keep them in a notebook.
- Extruders that only blow film will find Packaging Film Manufacturer Management 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
- Barcode and roll label printing
- Weighing scale input
- WhatsApp or other messaging
- Accounting software export
Questions owners ask before a demo.
Can a finished roll be traced to every film layer in it?
Yes. Each laminating run stores the reel lot of every layer and the adhesive batch. A roll opens to those lots, so a delamination query leads straight to the source reel.
How does it handle curing before slitting?
A cure period is set per structure. Rolls enter the slitter queue only after it has passed, and the planner sees them waiting in the curing room.
Can it follow cylinder life?
Metres printed are added after each run. The register flags a gravure cylinder or flexo plate that nears the wear limit your print room sets.
What if a brand changes its artwork?
A new artwork version is stored beside the old one. Open orders show which version they use, and the cylinders are marked for re-engraving.
Can pouch lines be managed with the same record?
Yes. Pouch counts, seal bar temperatures and rejects are logged against the laminate roll that fed the bag machine.
Does it support winding specifications per customer?
Core size, outer diameter, unwind direction and splice rules are stored for each customer and printed on the roll label.
Can we start with open orders?
Yes. Open orders, structures and film stock are imported from your files, and your planners check them against the floor before the first live roll.
Which records can we take out when we stop?
Roll histories, test results and customer records leave as files in the format set out in the quotation. Nothing is withheld at exit.
How is pricing decided?
Cost moves with the users, presses, laminators and pouch lines set up. You see a figure after we run your own roll and pouch orders on screen.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Flexible Packaging 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
Start with your requirements
Seven short steps that tell us what you need. An engineer reads them before getting in touch.
Share your requirements