Lines, dies, compound lots and cut-length orders tracked from hopper to bundle.
Every extrusion job runs through one record: quotation by weight per metre, die and vacuum sizing tank set-up, barrel zone temperatures, melt pressure, haul-off speed, regrind blend and bundle dispatch. A run carries its line, die number, compound lot and metres cut. Planners pick the line, operators key melt readings and scrap at the puller, and buyers get bundle tags that lead back to the run.
- Profile sections, dies and compound recipes entered with the names your plant uses
- Live orders, die records and compound stock carried over
- Profile and recipe changes done by us whenever you ask
Plastic Extrusion Company Management Software gives PVC pipe, HDPE conduit, window profile and sheet extruders one record per run. It holds die number, resin and masterbatch lots, regrind share, zone temperatures, haul-off speed, metres cut and scrap. Wall and ovality checks stay on the run. Every bundle tag leads back to it.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Enquiry and quotation
The enquiry names a pipe size and pressure class, a profile section or a sheet gauge, with the cut length and metres wanted. The quote uses weight per metre, line output and compound cost, and every revision is kept.
- 2
Die and trial
The die comes from the tool store or is made new. A start-up trial records zone temperatures, scrap and measured wall before the run is cleared for the buyer.
- 3
Line planning
The planner picks a line by size range and screw output, places colour changes so the lightest shade runs first, and checks resin, masterbatch and regrind for the whole run.
- 4
Running
The operator logs barrel temperatures, screw speed, haul-off speed and metres, with wall and diameter checks entered as the pipe leaves the sizing tank. Trim goes to the grinder.
- 5
Cutting and bundling
Lengths are cut at the planetary saw to order and counted into bundles. Tags print section, length, count and order number.
- 6
Dispatch
The delivery note lists bundles and metres, and the invoice follows from it. The die goes back to the tool store with its new metre count and a note on its condition.
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.
- Estimate/Quotation Management
A quote is priced from weight per metre, screw output and resin cost, and every revision stays beside the accepted figure.
- Production Planning
Haul-off speed, kilograms per hour and metres are logged per run, so the planner can compare real output with the quoted rate.
- Bill of Materials
Each section lists its resin, filler, stabiliser and colour recipe, and stock falls by those quantities as metres are produced.
- Batch and Serial Tracking
Purge, start-up scrap and regrind are weighed per run, so the blend behind a bundle can be reported back to the buyer.
- Quality Control
Wall, ovality and outside diameter readings are entered during the run, and a bundle outside limits is held until a supervisor releases it.
- Asset AMC Tracking
Metres through each die land add up with every run, and the service limit raises a flag before a worn die reaches the line.
- Order Management
Several buyers can share one section at different lengths, and the order list shows the metres and bundles still to be sawn.
- Barcodes and Labels
Tags print section, length, count and run for each bundle, so a wrong length is caught before the truck is loaded.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For owners and plant managers
Read line utilisation, scrap by cause, output against quoted rate and open orders in metres without a walk down each line. The numbers wait on one screen.
For planners
Choose a line for each section, place colour changes, and see when dies and compound will be ready. Clashes appear on the board before the shift.
For line operators
Log settings, output and scrap at the puller, and print tags as bundles are counted. Entry takes seconds on a tablet.
For the tool room
Follow metres through each die, plan polishing and note repairs between runs, so the tool room works from a list and not from complaints.
For quality staff
Enter wall and diameter checks, hold bundles outside limits and issue the results sheet a buyer asks for, with the run and compound lot printed on it.
The numbers the owner asks for.
- Line output in kilograms per hour against the quoted rate
- Scrap and purge by cause, line and colour
- Compound, masterbatch and regrind consumed per order
- Dies ranked by metres since polishing
- Dimensional check results by section and run
- Cut-length orders still open, in metres and bundles
- Bundles dispatched by buyer with run references
Who this is built for.
- Pipe extruders making water, drainage or conduit pipe
- Profile extruders supplying window, trim or channel sections
- Sheet and film extruders cutting to size or winding reels
- Co-extrusion plants running more than one extruder per line
- Extruders who hold a die shop for their own tooling
When it is not the right choice.
- A plant with a single line and one standing product can manage with a run sheet and a stock book.
- Companies whose main work is moulding solid parts or blowing bottles will find Injection Moulding Company Management Software or Blow Moulding Company 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
- Tablet entry at the line
- Barcode label printer
- Accounting export
Questions owners ask before a demo.
Does it work for pipe and sheet as well as profile?
It does. Each product family carries its own measured fields: wall and outside diameter for pipe, section dimensions for profile and gauge for sheet. The job picks up whichever applies.
How does it show the cost of a colour change?
Purge and start-up scrap are weighed and logged against the run. That weight, priced at compound cost, shows in the order result beside the colour change that caused it.
Can we trace a bundle back to a recipe?
Yes. The bundle tag names the run, and the run holds the resin, stabiliser, masterbatch and regrind lots with the line settings. A buyer’s query ends at a lot number.
Can two buyers share one run?
One extrusion can be split by length and metres across several orders. Each buyer’s bundles are tagged and counted separately, so the saw operator never guesses.
How is die wear handled?
Metres through the die are added with every run. A service limit per die flags it for cleaning or polishing before it is fitted again.
Can line speed come from the machine?
Not as standard, since operators key readings in. Where a line controller offers a data output, a feed can be quoted as an extra once the model is known.
Can the data be exported?
Yes, runs, checks and balances export to files. The fields in each export are fixed in the quotation, before any build starts.
What does the demo cover?
A section from your range goes through quote, die trial, a line run, bundle tags and a delivery note. A proposal with the figure follows the demonstration.
What support exists after go-live?
Questions and master data edits go to GullySystem staff. Line operators and planners get a refresher once the first weeks of runs are logged.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Plastic Extrusion Company 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