One system for film recipes, extrusion runs, gauge records and slit rolls.
Manage film recipes, resin and masterbatch lots, extrusion runs, gauge and treatment readings, slitting plans, regrind and customer deliveries in one system. Each jumbo roll carries its blend, its line settings and its thickness profile. Planners, line operators, slitter crews, quality staff and dispatch follow the same roll from granule to pallet. When a customer complains about one roll, the complaint lands on that roll’s record.
- Recipes, resin grades and specifications entered as your lines run them
- Open orders, roll stock and converter specifications brought across
- Changes to lines and reading types made by GullySystem staff on request
GullySystem configures Packaging Film Manufacturer Management Software around recipes, resin lots, extrusion runs, gauge readings and slitting at plants that make blown and cast film. Each jumbo roll records its blend, die settings and treatment level, and each narrow roll tag points back to it. Regrind, trim and certificates follow the same record.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and specification
A converter orders film by material, width, gauge, core and treatment level. The planner checks the saved specification for that converter.
- 2
Recipe and resin
A recipe is chosen, and virgin resin, masterbatch and regrind are reserved against it. Purchasing orders any granule that is short.
- 3
Extrusion
The operator starts the line and records die gap, speed and settings. Start-up film is weighed as scrap, and good rolls are tagged as they come off.
- 4
Readings
Thickness profile, dyne level and haze are recorded on each jumbo roll. A reading outside the converter’s limit holds the roll.
- 5
Slitting
Jumbo rolls are planned into customer widths. The slitter tag names its jumbo roll, and trim is weighed for regrind.
- 6
Pack and deliver
Rolls are wrapped, palletised and loaded. The pallet leaves with a certificate listing its readings, and the invoice is raised after it.
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.
- Price Lists and Schemes
Film is priced from the resin rate of the day, gauge, width and roll weight, and a converter’s agreed rate sits on file.
- Bill of Materials
A recipe lists each resin grade, masterbatch and additive share, and a locked version is what the operator loads.
- Stock Tracking and Alerts
Granule receipts and issues give cover in tonnes by grade, and a silo running low raises an alert to purchasing.
- Work Order Management
Each run sheet names line, recipe, die gap and operator, and lists the jumbo rolls and scrap it produced.
- Quality Control
Thickness profile and treatment level are entered per roll, and a reading beyond the converter’s limit holds that roll.
- Batch and Serial Tracking
Every narrow roll tag carries its jumbo roll number, linking it back to the resin lots and the run.
- Production Planning
Orders are matched to blown or cast lines by width and speed limits, and recipe changeovers are grouped on the board.
- Barcodes and Labels
Roll and pallet labels print with roll number and weight, matching the certificate that goes with the delivery note.
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 lines running, resin cover, rolls waiting to be slit, scrap and regrind share, and balances by converter.
For production planners
Assign orders to blown and cast lines, order resin and see which recipe changeovers can be grouped.
For line operators
Enter run settings and weights on a tablet at the line, and see the recipe for the order.
For quality staff
Review gauge, haze and dyne readings, hold a roll outside limits and issue certificates.
For slitter crews and dispatch
Follow the slitting plan, tag narrow rolls and load pallets against the delivery note.
The numbers the owner asks for.
- Jumbo rolls by line, recipe and reading status
- Resin and masterbatch used against film produced
- Scrap and regrind share by line and recipe
- Gauge variation by roll over a run
- Held rolls awaiting a decision
- Slitting trim by width plan
- Converter balances, oldest due first
Who this is built for.
- Blown film makers producing polyethylene bags and wrap film
- Cast and oriented polypropylene film producers
- Multilayer coextrusion plants that supply laminators
- Film makers who slit to converter widths on their own slitters
- Extruders asked by converters for a certificate of readings with each roll
When it is not the right choice.
- A small plant that makes a few carry bags on one machine can work from a run book.
- A plant that prints and forms pouches needs Food Packaging Manufacturer Management Software, and a drum maker is nearer to Industrial Packaging Manufacturer Management Software.
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
- Gauge scanner file import
- Weighing scale input
- Roll label printing
- WhatsApp or other messaging
- Accounting software export
Questions owners ask before a demo.
Can a roll complaint be matched to the run that made it?
Yes. The roll tag opens the run sheet, with the recipe, die settings, resin lots and gauge profile recorded. Any streak complaint is checked against the roll’s own readings.
Where does regrind get recorded?
Trim is weighed at the granulator and the share returned to a recipe is logged. The recycled share per roll is calculated, and your quality staff set the limits a recipe may use.
Can narrow rolls be traced to the jumbo roll?
Yes. The slitting plan keeps the parent roll against every narrow roll, with the tag printed at the slitter.
Does it read the line scanner directly?
Operators can key a profile in, or a scanner export can be loaded once the run is over. A live link to a particular scanner is separate integration work, written into the quotation.
Can different converters have different limits?
Yes. Gauge tolerance, dyne level and core size are stored per converter. A roll is checked against the limits of the order it is made for.
How is resin cover calculated?
Receipts and issues by grade give stock in tonnes. Open orders and their recipes show how many days of each grade remain, and a low-cover warning goes to purchasing.
Can we bring over our recipe sheets?
Yes. We load your recipe sheets and converter specifications, and the line leads read them back before the first live run.
What happens to our records if we leave?
Run sheets, readings and roll records can be exported whenever you like, in the format the quotation names. The format is fixed before work starts.
What drives the price?
The figure grows with the number of named users and with each extruder, winder and slitter added to the setup. Sample film runs are shown on screen first, then the quotation gives the figure.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Packaging Film 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