BOPP, CPP and PET film through gravure print, lamination, slitting and pouch making on one traceable system.
Manage quotations, film structures, artwork proofs, gravure cylinder records, mother reel and child reel tracking, stage-wise scrap, dyne and seal checks and pouch dispatch in one system. Every reel carries its parent film lot, the machines it passed and its weight at each stage. Planners see which press and laminator stand free. Operators weigh reels at the machine. Cartons trace back to the film.
- Film structures, artwork and cylinder records entered with the names your press room uses
- Live orders, reel stock and cylinder rack locations carried over
- Structure, ink and artwork changes carried out by us when requested
Film and pouch makers track BOPP and CPP structures, artwork proofs, gravure cylinders, reels, scrap and stand-up pouch dispatch in Plastic Packaging Manufacturer Management Software. Every mother reel and slit child reel carries its weight, metres and machine history. Scrap is totalled across extrusion, print, lamination and bagging. Cartons trace back to the film lot.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Specification and quote
The brand owner’s pouch size, gusset, zipper and film structure are recorded together with the colour count. The quotation converts pouches into film metres and kilograms.
- 2
Artwork and cylinders
Artwork revisions are logged and the proof is approved. Cylinders or flexo plates are then made and entered with their owner and rack location.
- 3
Extrusion and print
Base film reels are numbered and weighed. Corona treatment is checked, and print runs record the Pantone match approval and the waste at start-up.
- 4
Lamination and slitting
Printed reels are laminated to the sealant film with solventless or solvent adhesive and slit to width. Each child reel is numbered under its mother reel.
- 5
Conversion
Pouch and bag machines make the finished goods. Counts, bottom seal checks and rejects are logged by reel.
- 6
Packing and delivery
Pouches are counted into cartons and pallets. Labels and delivery notes carry the film lot.
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
Pouch counts turn into film metres and kilograms, and the price carries the expected scrap of each stage for that structure.
- Bill of Materials
Each layer’s polymer, micron, adhesive and ink are stored per pouch type, so a repeat order starts from the same build.
- Workflow and Approvals
A proof moves through the brand owner’s sign-off, and a run is held if the approved artwork differs from the engraved cylinder.
- Asset AMC Tracking
Cylinders and plates are listed with owner, rack position and impressions run, and the artwork revision each was made from.
- Batch and Serial Tracking
Child reels carry their mother reel’s number through slitting, so a carton of pouches traces back to the film lot.
- Production Planning
Jobs are sequenced across extruders, presses, laminators and slitters by web width and colour count to cut changeover time.
- Quality Control
Dyne level, bond and seal strength results are held against the reel, and a failed reel waits for a supervisor’s decision.
- Barcodes and Labels
Carton and pallet labels print the film lot and order, so a customer query leads straight to the reel record.
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 scrap across every stage, machine loading and orders heading for an overrun without chasing each department. One screen.
For planners
Sequence reels across extruders, presses, laminators and slitters, with web width and colour changes held to a minimum.
For press and laminator operators
Weigh reels in and out, record scrap and note the approved Pantone match from a tablet beside the press.
For quality staff
Test dyne level, bond and seal strength, hold failed reels and print results for the brand owner.
For artwork and prepress staff
Log revisions, record proof approvals and link each cylinder to the revision it was engraved from.
The numbers the owner asks for.
- Total scrap per order, split by stage
- Reel genealogy from film lot to carton
- Artwork proofs awaiting approval
- Cylinders by owner, rack position and impressions
- Seal, bond and dyne results by order
- Machine loading by web width and colour count
- Pouches dispatched by customer with film lot references
Who this is built for.
- Film extruders who also gravure print and laminate
- Converters making stand-up pouches and side-weld bags from bought-in BOPP
- Makers of printed shrink sleeve and stretch films
- Packaging firms that engrave or buy gravure cylinders
- Companies supplying retort and snack pouches to food and agrochemical brands
When it is not the right choice.
- A small bag maker who cuts plain film and sells by weight can manage with a stock book and a delivery note.
- Companies whose products are moulded bottles or hard components will find Blow Moulding Company Management Software or Injection 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 machine
- Weighing scale
- Barcode label printer
- Accounting export
Questions owners ask before a demo.
How does it follow a reel through slitting?
Every slit width becomes a numbered child reel linked to its mother reel. The finished carton then traces back through those numbers to the original film lot.
Can it convert pouches to kilograms?
Yes. A pouch type stores its dimensions, gusset, film structure and gauge, so an order quantity turns into running metres and kilograms for planning and costing.
How does it control artwork versions?
Each artwork revision is logged with its approval. A gravure cylinder is tied to the revision it was engraved from, and a mismatch is flagged before the run.
Can cylinders owned by customers be listed separately?
Yes. Owner is a field on the cylinder record, so your own and your customers’ cylinders can be reported as separate lists.
Can scales feed weights straight in?
Not by default, because operators key weights in at the machine. A floor scale with a data port can be connected as a scoped extra once the model is known.
What does the waste figure include?
Trim and start-up scrap logged at extrusion, print, lamination, slitting and bagging for the order, set against the allowance for the structure.
Can we export reel and order history?
Reel records, test results and order history export to files. The format is agreed before work begins.
What happens in the demo?
A pouch of yours goes through quote, artwork, cylinder, reel numbering, slitting and carton labels. A proposal with users, machines and cost follows.
How is plant staff trained?
Operators learn weighing and scrap entry at their own machine. Planners and quality staff are trained on their screens, and GullySystem staff handle edits afterwards.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Plastic 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