Reel to carton on one record, with trim and set-up waste weighed at every machine.
Every reel is booked by mill, lot, grammage, width and core weight, then followed through slitter, ruling machine, folder, pasting line and stitching head with trim weighed after each cut. Planners read expected pieces per reel before a blade is set. Dispatch packs reams, dozens and cartons against the order.
- Notebook, envelope and bag formats entered with their paper, board, thread and glue allowances
- Reels on the rack weighed and migrated with grammage and width
- Machine and product changes made by GullySystem staff when asked
Each reel is booked by mill, lot, grammage, width and core weight, then followed through slitting, ruling, folding, pasting and binding, with the trim strip weighed after every cut. Planners read expected notebooks per reel before the slitter runs. Set-up waste lands on the order that caused it.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and bill of materials
Order logged. Its bill of materials names the text paper, cover board, stitching wire, glue and the trim allowance agreed for that format, so the paper need is known early.
- 2
Reel selection
Reel chosen by grammage and width. The system counts the pieces a reel should yield, after taking off the core weight. That figure shows before the rewinder is set, so no trial cut is wasted on a guess.
- 3
Slitting and sheeting
Cut and weigh. The reel goes to the slitter and is cut to sheet size, then every stack is weighed and trim strips and leftover core are written against the reel number.
- 4
Conversion
Ruling, folding, pasting, stitching or case binding runs are logged by machine, with pieces made and waste beside the operator’s name. Set-up sheets stay apart from running spoilage so each can be judged alone.
- 5
Counting and packing
Reams, dozens, bundles. Packers count each reams-and-bundles lot into a labelled carton, then match the carton tally to the order line before any strapping or shrink wrap is applied.
- 6
Dispatch and invoice
A delivery note is printed from the packed cartons. The invoice follows under your local tax rules, and any short count is carried forward as an open balance on the order.
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.
- Batch and Serial Tracking
Each reel keeps its mill, lot, grammage and width, so a wrong substance found in a notebook run traces straight back to the rack position it came from.
- Bill of Materials
Text paper, cover board, stitching wire, glue and trim allowance are listed per notebook, envelope or bag, so product cost finally carries the small items.
- Production Planning
The planner sets open conversion orders against reels on hand and reads expected pieces per reel before any slitter blade is moved on its arbor.
- Work Order Management
Each run is logged by machine with pieces made, set-up waste and run waste apart, so the cost of a pen bar changeover lands on the right order.
- Stock Tracking and Alerts
Paper below its reorder level raises a purchase suggestion, and reels received are weighed against the figure printed on the merchant’s bill.
- Barcodes and Labels
Pack labels printed at the counting table carry product, count and batch, so each carton is matched to its order at the dispatch gate by scan.
- Order Management
Customer orders by item and quantity are matched to packed cartons, and a short shipment stays open until the balance is delivered and signed for.
- Dashboards and KPIs
Output by machine and shift sits beside downtime reasons such as web breaks, so the owner reads the day without walking the floor.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For owners
Read paper bought, waste by machine and margin per order. Notebook cost comes from the reels actually drawn, not from last year’s rate card for foolscap, so quotes stop leaning on old figures.
For production planners
Choose reels and release orders to the ruling and pasting machines. The queue per machine and every order waiting on paper sit on one screen instead of a whiteboard of magnets.
For machine operators
Tap pieces made, waste and downtime at the machine. The next order in the queue sits on the same screen, with its sheet size and ruling pattern shown.
For the paper store
Receive reels, weigh part reels back and issue paper against a conversion order. Every issue names the reel, so the rack never holds an unlabelled core or a mystery half-roll.
For packing and dispatch
Pack cartons to the order count, print labels and delivery notes, and mark the order shipped. Short dozens show up at the packing bench and not at the vehicle, where fixing them costs a trip.
The numbers the owner asks for.
- Reels received and issued by mill, grammage and width, with core weights
- Trim strips and set-up waste by machine and by order, split from run waste
- Expected yield against actual notebooks or envelopes per reel after slitting
- Part-used reels on the rack with weighed core and remaining width
- Orders waiting on paper, on a ruling machine or on a cover board delivery
- Cartons packed against customer orders, with dozens short by line
- Paper, wire and glue cost per thousand pieces by product and ply
Who this is built for.
- Exercise book and notebook makers converting reels into ruled, stitched and case-bound books
- Envelope and paper bag manufacturers running pasting and tube-forming machines
- Makers of file covers, folders and pad stationery
- Converters that buy reels from several mills and merchants
- Packers that deliver by ream, dozen, bundle and carton
When it is not the right choice.
- A business that mainly prints jobs for customers will find Commercial Printer Management Software closer.
- A mill that makes the paper itself needs process-plant software, not a converter’s system.
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
- Weighing scale entries
- Barcode label printing
- SMS
- Accounting export
Questions owners ask before a demo.
Can it follow a reel through several machines?
Yes. A reel is issued to the slitter, then each output stack moves on to ruling, folding or binding, with kilograms and sheet counts written at every handover between machines.
How does it treat a part-used reel?
The leftover core is weighed and relabelled when a job ends. Its new weight, grammage and width appear in stock, so the next planner can load it without guessing at what the chalk mark meant.
Can we cost a notebook from real paper used?
Yes. Kilograms drawn from the reel and trim strips are added to set-up waste, board, thread and glue from the bill of materials. Cost per thousand pieces then appears on the order.
Does it handle envelopes and bags as well as books?
Envelopes, bags and books each carry their own bill of materials and route through different machines. A pasting run for envelopes and a ruling run for exercise books are logged in one way.
How are cartons matched to orders?
Packing records the dozens or reams in each carton against an open order. A short count shows on the packing bench, well before the vehicle leaves the gate with the wrong count.
Can the store check weights from a scale?
Weights can be keyed in at the store. A scale file import can be added as extra work, agreed at the start and written into the quotation.
Do operators need a computer at the machine?
A tablet or wall screen at the machine is enough, and operators tap pieces made, waste and downtime. It needs a network connection, and a wired port is the sturdier choice near a folder or pasting line.
Can we import our stock list?
Yes. The register you keep now is read in, covering reels, sheet stacks and orders still open, and the paper store counts a sample against the racks before go-live.
Who owns the data?
You do. How your reel, run and order history is handed back to you is agreed and recorded in the quotation, ahead of any build work.
What does it cost and is there a trial?
Machines and users shape the cost. A demo comes first, with one of your notebook or envelope lines run on screen, and only then do you receive a quote in writing.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Paper 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.
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- 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.
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