Container specifications, resin lots, moulds and closure fit tests on one batch card.
Container drawings, PET resin and preform lots, injection and stretch blow machine boards, mould and cavity cards, closure fit tests, carton patterns and invoices are kept together. Each order carries its volume, neck finish, gram weight and colour, and each batch carries the resin lot and mould it came from. Planners, setters, lab technicians and dispatch clerks read one batch card, from the filler’s first drawing to the shrink-wrapped pallet.
- Neck finishes such as PCO 1881, volumes and gram weights typed the way each filler quotes them
- Customer list, mould cards and resin stock copied in before the first batch
- Later machine and test-rule edits carried out by our team when asked
Makers of bottles, jars, tubs and caps keep orders, container drawings, resin lots, moulds and test cards in Rigid Packaging Manufacturer Management Software, which GullySystem configures to the plant. Each batch links its resin lot, mould and live cavities to the top-load, torque and leak readings. Carton counts and pallet layers follow each filler’s pattern into the delivery.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Drawing and quote
A filler sends volume, neck finish, gram weight and colour. The estimator prices resin weight, cycle time per cavity and tooling, then keeps the sum beside the drawing.
- 2
Specification approval
Container and closure are confirmed against the filler’s saved drawing. The signed sample is recorded.
- 3
Resin and mould check
PET or HDPE resin is dried to the hopper dew point and issued by lot. The mould is checked for shot count, live cavities and condition before it leaves the rack.
- 4
Moulding or blowing
The setter fits the mould, approves the first-off and logs shot weight and cycle time through the shift. Short shots are written against the cavity.
- 5
Decoration and testing
Containers are pad printed, labelled or sleeved if required. Weight, wall thickness, top-load, torque and leak samples are tested.
- 6
Packing and dispatch
Containers are packed to the filler’s carton and pallet pattern, with slip sheets and wrap noted. The packing list carries lot, count and layers.
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.
- Quote & Proposal Management
Prices are built from resin weight, cycle time, cavity count and decoration, and a reorder sits beside the earlier quote.
- Goods Receipt (GRN)
Resin, colour and preforms are booked on arrival with lot and dryer history before the setter can draw them from stores.
- Batch and Serial Tracking
Each batch carries its mould and live cavities, so a returned bottle can be followed back to a cavity and a resin lot.
- Production Planning
Orders are sequenced by mould, colour and resin to cut purging, and the board shows which machine runs what this week.
- Quality Control
Weight, wall thickness, top-load, cap torque and leak readings are entered against the batch, and a failing lot is held.
- Fixed Asset Register
Each mould is listed with shots run, blocked cavities, polishing and repairs, with a flag when it nears the service limit.
- Barcodes and Labels
Carton labels print in each filler’s pattern, and the packing list shows lot, count per carton and layers per pallet.
- Job Work Management
Printing, labelling and sleeving steps, whether in-house or sent to an outside sleever, carry the counts out and back.
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 batches running, resin cover, moulds due for service, rejects by cavity and balances by filler on one screen.
For planners
Book machines and moulds, group like colours to save purging and move jobs when a mould is held for repair.
For setters and operators
Read the job, record first-off and shot data, and report a blocked cavity from the machine.
For quality staff
Key in weight, top-load, torque and leak readings, then pass a batch or put it on hold.
For stores and dispatch
Dry and issue resin, pack to each filler’s pattern and print carton labels at the pallet.
The numbers the owner asks for.
- Batches by machine with test status
- Resin consumed against shot weight
- Rejects by cavity, cause and shift
- Moulds by shots since last polish or service
- Top-load and leak results per batch
- Pallets dispatched by filler and pattern
- Open invoices per filler, oldest at the top
Who this is built for.
- Makers of PET bottles and preforms for drink and edible oil fillers
- Injection moulders of caps, jars and tubs for food and cosmetics
- Plants that run stretch blow, extrusion blow and injection machines together
- Container makers that decorate by pad print, hot stamp or sleeve
- Companies whose fillers ask for neck gauge, torque and leak records
When it is not the right choice.
- A small moulder who runs a few thousand lids for one customer can get by on a paper job book and a wall chart.
- Pouch and rollstock converters are better served by Flexible 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
- Barcode and carton label printing
- Bench scale and torque tester input
- WhatsApp or other messaging
- Accounting software export
Questions owners ask before a demo.
Can a batch be traced to its resin lot and mould?
Yes. Each run records the resin lot, the mould and the live cavities. A batch opens to all three, and a returned bottle can be followed back to its cavity.
How are cap and bottle checks recorded together?
A fit test is entered against the container batch and the closure batch it used. If the pair leaks or strips, both are held until quality staff decide.
Can it count shots on every mould?
Yes. Shots are added from each run, and the register shows which mould is nearing the polish or service limit set by your toolroom.
Does it help with colour changes on the machine?
Yes. The planner groups orders by colour and resin so that light shades run before dark ones. The sequence rule is agreed with your own production staff.
Can decorated containers be tracked as a separate step?
Yes. Pad printing, labelling and sleeving are queued behind moulding, and the count carried forward shows how many containers are still plain.
How does it handle fillers with different pallet patterns?
Count per carton, cartons per layer and layers per pallet are stored per filler and printed on every carton label and packing list.
Can we start with open orders?
Yes. Open orders, container drawings and resin stock are copied in from your files. Planners match them against the floor before any live batch is run.
What do we take with us if we stop using it?
Batch cards, mould histories and test results can be handed back as files in the format stated in the quotation. Nothing is held back at exit.
How is pricing arrived at?
Cost rises with users, injection and blow machines and moulds set up. A figure is given after a demo that uses your own bottle and cap orders.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Rigid 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