Link every mould, resin lot, colour change and carton to the bucket, mug or crate it produced.
Every mould, resin lot and colour change is written on the job record for the buckets, mugs and crates you make. Each run notes the mould, the masterbatch lot, the colour and the sample weights, so a light bucket or an off shade is caught at the press. Dealer orders ship against carton stock.
- Your colour range and size list keyed in as buyers order it
- Resin stock, mould list and wholesaler orders brought over before start
- Changes to products and run fields handled by GullySystem staff when asked
Buckets, mugs and storage boxes are planned, moulded, reground, packed and dispatched from one record that holds the mould list, masterbatch lots and every colour change between runs. Samples are weighed. Light handles and off-shade lids are caught at the press, long before a pallet reaches a dealer.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Orders and plan
Wholesaler and chain orders by size and colour become a moulding plan, with runs grouped so light colours go before dark ones and purge stays small.
- 2
Setting up the mould and resin
The setter fits the mould and clamps it to the platen. Resin and masterbatch are issued by lot, and the regrind share allowed is set before the first shot is fired.
- 3
First-off and run
First-off pieces are weighed and checked for flash, sink marks and lid fit, and the run then logs shots, good pieces, rejects and weight samples drawn from each cavity.
- 4
Regrind and scrap
Sprues, runners and rejects are weighed and sent through the granulator, and the share returned to later runs is recorded against each job, hopper by hopper.
- 5
Printing and packing
Pieces are trimmed, hot stamped or screen printed where needed, nested, counted and cartoned with a label carrying size and colour.
- 6
Dispatch
Cartons leave against orders on delivery notes, and stock by size and colour falls as each pallet is loaded at the dock. Counts match what left the dock.
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.
- Fixed Asset Register
Each mould is listed with cavities, shots run and repair notes, so a blocked cavity is known before the next job is booked on that tool.
- Production Planning
Orders by size and colour become runs grouped by colour order, which keeps the purge between runs short and the dark shades last.
- Batch and Serial Tracking
Granules and masterbatch are tracked by lot and colour, so a pallet with an odd tone traces back to the drum that coloured it.
- Work Order Management
A work order per mould job records shots, good pieces, rejects, weight samples and cycle time by machine and shift, so a slow press shows up.
- Quality Control
First-off weight, finish and lid fit are checked and signed by the setter and the approver before a run is released.
- Stock Tracking and Alerts
Cartons are counted by size and colour, and an alert appears when a fast moving shade drops below its reorder level.
- Order Management
Wholesaler and chain orders are held by item, size and colour, and each dispatch reduces the open balance on the order.
- Barcodes and Labels
Carton labels carry size, colour and count, so a pallet can be checked against the order before it leaves the dock.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For setters
See the mould, resin lot and machine settings for the job, log first-off weight, then approve the run. A short shot is caught here.
For machine operators
Record shots, rejects and shot weight samples at the press, and weigh sprues and runners for the granulator, so the regrind share used is on the job and not guessed.
For the resin store
Receive granules and masterbatch by lot and colour, then issue them to the hopper against a named job, so a drum of pigment can always be traced to the run.
For planners
Group runs by colour order, check which moulds are free of repairs and read stock by size and colour before fixing the week.
For dispatch and sales
Pack and label cartons, dispatch against orders, and read dealer balances line by line before the vehicle is loaded and the delivery note is signed.
The numbers the owner asks for.
- Shot weight against target by mould and shift
- Purge resin and minutes lost to colour changes
- Regrind share by job and machine
- Mould shots and repairs due
- Resin and masterbatch stock by lot
- Finished stock by size and colour
- Dealer orders open and dispatched
Who this is built for.
- Makers of buckets, tubs and mugs
- Manufacturers of storage boxes, baskets and crates
- Plants that mould stools, chairs and household furniture
- Blow moulders of jugs and household bottles
- Manufacturers that supply retail chains with branded plastic ware
When it is not the right choice.
- A plant that moulds technical parts to customer drawings, with gate location and tolerance reports, will find Plastic Component Manufacturer Management Software closer than this one.
- A factory making only packaging film on extrusion lines will find Packaging Film Manufacturer Management Software closer, because it works from reels and slitting rather than moulds.
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
- Weighing scale export
- Accounting export
Questions owners ask before a demo.
Can weight limits be set for each product?
Yes. A target weight and a tolerance band sit on the mould record, weight samples are compared with them, and a reading outside the band is flagged to the setter at the press.
Does it cover injection and blow moulding?
Yes. Each mould or die is tagged with its machine type, so blow lines record parison weight and bottles made, while injection lines record shots and the cavities in use.
How do colour changeovers get costed?
Purge resin and minutes are logged on each change, and reports sort them by colour pair, so the planner sees which sequences cost most in granules and press hours. Each pair gets its own cost.
Can we limit the regrind used in a product?
Yes. The allowed regrind share is set on the product, the operator enters the share actually used, and any higher figure is flagged to the setter before the next shot run.
How is a mould’s life tracked?
Every job adds its shots to the mould. Welding, polishing and blocked cavities are noted against it, and a service flag appears at the shot count you choose for that tool.
Can orders be taken by colour and size?
Yes. Orders list item, size, colour and quantity, so planners see demand by colour before they build the moulding plan for the week.
Can the shade of a masterbatch lot be traced?
Yes. The lot is recorded on the run, so a pallet showing a different tone can be matched with the masterbatch drum that coloured it.
Can open orders and resin stock be moved across?
Yes. The resin store and the dispatch bay count stock against the imported figures before the first live run, and any gap is corrected.
Does it work for contract moulding too?
Yes. A customer’s mould can be held as a customer asset with its own job records, so household lines and contract jobs sit side by side.
Who looks after it after go-live?
GullySystem staff make changes to products, fields and layouts on request, from a new carton label to an extra weight check on the mould record. Larger changes are quoted before work begins.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Household Plastics 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