One connected system for paper conversion, pen assembly, variants and dealer orders.
Variant item codes, maplitho reels, guillotine and ruling runs, offset cover plates, saddle stitching, pen barrel assembly, PVA glue lots and dealer sets share one record. Every exercise book carries its reel, its spoilage and its carton. Term stock is visible by variant, months ahead.
- Variant codes, reel sizes and pack sizes entered as your planners define them
- Open dealer orders and finished stock migrated
- Edits to item options and routes handled by GullySystem staff when asked
Maplitho reels, guillotine trim, saddle stitching, pen barrel assembly and dealer school sets are handled in Stationery Manufacturer Management Software, which GullySystem configures for notebook, pen and file makers. Sheets cut from each reel, spoilt covers, refills issued and packs counted are recorded at each step. Short variants show before an order is promised.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Dealer order and forecast
Dealer orders arrive by item code and a pack of ten or twenty, next to the school term forecast. Each is keyed once and checked against packed stock for that exact cover and ruling.
- 2
Plan and material
Planners match runs to maplitho reels, duplex board, barrels, refills and ink drums, then raise a purchase request for whatever the store cannot cover. Shortfalls show before cutting begins.
- 3
Cutting, ruling and printing
Reels are cut to sheet size on the guillotine and ruled on the ruling machine. Offset covers print by artwork code. Each run notes spoilt first pulls and the minutes lost on plate change.
- 4
Binding and assembly
Sections are folded, gathered and saddle stitched, or perfect bound with hot melt under a cover. Pen lines press tips, fit refills, fill ink and count boxed packs by the hour.
- 5
Check and pack
Samples are checked for ruling alignment, cover registration, spine pull and ink flow. Passed goods go into shrink-wrapped packs, inner boxes and master cartons with the count on the label.
- 6
Dispatch
The packing list, delivery note and invoice leave against the dealer order. A short variant shows as a back order. The rest of the carton count stays reserved.
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 cover, ruling and pack size combination carries its own bill of parts and route, so the stitching line builds the right book.
- Product Management
Hundreds of variant codes grow from the option lists you define, rather than being typed one by one for every pen colour or notebook size.
- Batch and Serial Tracking
Ink drums and hot melt lots link to the pen or book batches they went onto, so a complaint leads straight to one lot.
- Production Planning
Packed and semi-finished stock by variant is set against the term forecast, and runs and reel purchases are planned from the gap.
- Work Order Management
A binding run opens for one variant and quantity, gathers counts and spoilage by shift, and closes with the number of books passed.
- Quality Control
Ruling, registration, spine pull and ink flow results are recorded on samples, and a failing batch is held before packing.
- Stock Tracking and Alerts
Reels and board are tracked by width, GSM and lot, with an alert when cover for the next guillotine runs falls short.
- Order Management
Dealer orders are held by variant code and pack size, with a back order shown for the one item that is short.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For plant owners
See sheets per reel, term stock by variant, dealer orders held, and what a short cover run really costs after plate swaps.
For planners
Match dealer orders and forecasts to reels, covers and pen parts, then sequence guillotine, ruling and press runs so board arrives before it is needed.
For paper store staff
Book in each reel and board stack by lot. Weigh it out to the guillotine and note the core left over.
For line supervisors
Enter sheets, books stitched, pens assembled and spoilage on a tablet at the machine, and see which run is next in the queue.
For packing and dispatch
Pack inner boxes and master cartons to the list, print carton labels and mark back orders for the missing variant.
The numbers the owner asks for.
- Sheets cut per reel, with trim and spoilage
- Cover print batches by artwork code, plate swap minutes and spoilt first pulls
- Barrels, tips and refills issued against boxed pens assembled
- Ink drum, hot melt and lacquer lots against the batches where used
- Packed stock by variant against the term forecast
- Dealer orders held, naming the short variant
- Ruling, registration and spine pull results, with batches on hold
Who this is built for.
- Notebook, exercise book and paper pad makers
- Pen, pencil and marker manufacturers
- File, folder and board stationery makers
- Producers of school sets and geometry boxes
- Plants that print covers and bind in-house
When it is not the right choice.
- A small printer who binds a few custom diaries each month can manage with job sheets and a ledger.
- Presses whose main work is commercial jobs for clients will find Printing Press 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
- WhatsApp or other messaging
- Barcode and label printers
- Tablet entry at the line
- Accounting export
Questions owners ask before a demo.
Can the same system run notebooks and pens?
Yes. Paper conversion and pen assembly keep separate routes and parts lists. Both feed one finished stock view by variant, so a school set can mix a notebook, a pen and a file.
How is paper wastage worked out?
Reel weight is recorded on receipt. Sheets cut, ruled and bound are counted against it, and the gap appears as edge trim and spoilage for each reel.
Can a cover printing changeover be recorded?
Yes. Operators note the plate or colour swap, the minutes it took and the first pulls thrown away. Every cover run then shows its true cost.
What if a pen batch writes badly?
The ink drum and refill lot used in that batch are recorded. Cartons carrying them can be found and held before they reach a dealer.
How do dealer sets work?
A set is one order with several item codes. The system names the single short variant, so nothing else is packed ahead of it and left blocking the dock.
Can our existing codes and stock be loaded?
Yes. Item codes, reel stock, packed stock and open dealer orders are imported. Your planners check a sample against the old registers before go-live.
Does it work out cost per notebook?
It adds paper, cover, ink, labour hours and outside binding work to each variant, using the rates you give. Costing rules are agreed at set up.
Can supervisors enter data on the floor?
Yes. Line supervisors use a tablet or phone browser to enter counts, spoilage and downtime beside the machine. Entries save as they are made.
Who owns the production data?
You do. Before work begins, the proposal says how reel, batch and order records can be exported.
How is it priced?
Price depends on plants, lines and users. We demo with your own notebook range first, then send 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 Stationery 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