Resin recipes, reactor cooks, test values and drum filling kept in one plant system.
Run a resin plant from the monomer tank to the drum on the truck. Recipes, reactor cook records, in-process samples, final test values, rework, bulk tanks, drum filling, certificates and orders are held together. Operators post charges and steps at the reactor. The laboratory posts acid value, viscosity and solids against the cook, and the office sees which lots are ready to ship.
- Grades, recipes and test limits entered as your plant cooks them
- Customers, open orders and tank stock migrated
- Certificate layouts reviewed with your own laboratory head
Alkyd, polyester, epoxy and acrylic resin plants keep recipes, reactor cooks, laboratory values, rework, tank and drum filling and dispatch in Resin Manufacturer Management Software from GullySystem. Each drum traces to its cook and its test values. Orders, certificates and monomer stock are tracked, so a question about a grade opens one record.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Raw material receipt
Monomers, glycols, acids, oils and solvents are received with supplier lot and posted to tanks and stores.
- 2
Recipe and charge
The cook starts from the recipe revision. Charge weights, catalyst and starting temperature are posted at the reactor. Nothing waits for the office.
- 3
Cook and sample
Temperature steps and water of reaction are recorded. Samples for acid value and viscosity are posted until the target is reached.
- 4
Finish and test
The batch is cooled, thinned if needed, filtered and tested for colour and solids. Release or hold is recorded.
- 5
Fill and dispatch
Resin goes to drums or a bulk tank, drum numbers are posted, and the certificate and delivery note are produced for the load.
- 6
Cost and review
The cook’s cost is built from the actual charges and compared with the recipe.
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.
- Bill of Materials
Each grade lists monomers, glycols, acids and catalyst with quantities and temperature steps, and each cook keeps the revision it followed.
- Production Planning
Cooks are scheduled by reactor and grade, then record charges, steps and water collected as they run.
- Batch and Serial Tracking
Resin moves from reactor to holding tank to drum, and the record shows which cooks sit in which drum run.
- Quality Control
Colour, solids, gel time and viscosity are checked against the grade limits, and an off-limit lot waits for a named decision.
- Goods Receipt (GRN)
Monomer and solvent tankers are weighed in against the delivery note and posted to tanks with supplier lot and dips.
- Work Order Management
Each cook runs as a work order, and every sample taken during it is posted with its acid value and viscosity against the target.
- Order Management
Orders reserve released lots by grade and pack, then flow into delivery notes that carry the cook numbers sent.
- Document Management
The certificate for a lot is stored with its delivery, so a customer can ask for the figures again after the drums are used.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For the plant manager
See reactors running, lots on hold, drums filled and monomer stock on one board.
For reactor operators
Post charges, steps and samples from a handheld device at the reactor, with the recipe on the screen. No paper is carried.
For laboratory staff
Enter acid value, viscosity, solids and colour against the cook and apply the grade limits.
For sales and dispatch
Match orders to released lots, print certificates and delivery notes, and follow dues.
The numbers the owner asks for.
- Cooks by grade with final acid value and viscosity
- Lots on hold, with the failed value
- Rework quantities by cook and approver
- Drums filled by cook and tank
- Raw material consumption against recipe
- Batch cost against recipe cost
- Customer dues by invoice age
Who this is built for.
- Makers of alkyd and polyester resins for coatings
- Producers of epoxy and phenolic resins for laminates and adhesives
- Acrylic resin plants supplying paint and ink makers
- Casting resin and binder producers for foundries
- Resin makers that sell in drums and in bulk tankers
When it is not the right choice.
- A distributor who stores sealed resin drums and resells them as received needs only stock and billing, not a reactor record.
- Plants that mainly make solvents or water treatment chemicals will find the matching manufacturer 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
- Weighbridge
- Barcode and label printers
- Accounting export
- Laboratory instruments by file import
Questions owners ask before a demo.
What does an operator post at the reactor?
Charges by weight, temperature steps, the time of each sample and the water of reaction collected. The recipe sits on the same screen. Nothing is copied later.
How are in-process samples used?
Each sample value is plotted against the target, so the supervisor can see whether the cook is converging before deciding to hold or finish.
How is a thinned batch shown on the certificate?
The final values are those posted after thinning, and the correction stays on the batch for anyone who asks what was done.
Can one grade carry different customer limits?
Yes. A grade can hold customer-specific limits beside the standard ones, and the certificate uses the set linked to the order.
Can it work out the cost of a batch?
Yes. It builds the batch cost from the charges posted and the current raw material price, then shows the difference from the recipe.
Can we run bulk tankers and drums from the same stock?
Yes. Bulk and drum dispatches draw from released lots and tanks, each with its own delivery note.
How can we see it before buying?
A working session is run with a few of your recipes and cooks, and the proposal reflects the number of reactors and users.
Can the records leave the system?
Cook logs, laboratory values, certificates and orders can be exported to spreadsheets laid out as the agreement specifies.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Resin 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