One system for bale lots, mixing plans, frame counts, lab readings and cone despatch.
Manage a spinning mill in one system. Bale lots are recorded with their fibre tests and laid into mixing plans by count. Production and waste are captured by department and shift, ring frames are allocated to orders, and the lab attaches its readings to each lot. Cones are packed, labelled and despatched against the buyer’s order, with the report that goes with them.
- Counts, blends and department list entered as your mill runs
- Open orders and bale stock brought over from your registers
- Count and waste head changes made by GullySystem staff on request
Spinning mills making carded, combed or blended yarn can keep the whole chain on one record. Each bale lot, mixing plan, frame run and lab reading sits on the lot record. Planners, department heads, the lab and the despatch clerk work from it, and the cone label carries the lot back to its bales.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Order and plan
A buyer’s order is entered with count, blend, cone weight and quality limits. The planner picks frames and a mixing plan for it.
- 2
Bale intake
Bales are weighed against the supplier’s delivery note and logged with their lot and fibre test. They are binned in the warehouse until called.
- 3
Preparation
The mixing room lays down the plan. Blow room, cards, combers and drawing frames record production and waste for each shift.
- 4
Spinning and winding
Roving goes to the allotted ring frames, bobbins are doffed and wound into cones, and stoppages are logged with a cause.
- 5
Testing
The lab samples the lot, enters its readings and marks the lot accepted or held for rework or regrading.
- 6
Packing and despatch
Cones are packed to weight, labelled with lot and count, and listed on a packing list that matches the buyer’s order.
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.
- Goods Receipt (GRN)
Each bale is weighed against the supplier’s delivery note on arrival, and a short or damaged bale is noted before it reaches the warehouse.
- Bill of Materials
A mixing plan holds the bale lots and their share for one count, so the same blend can be laid down again.
- Production Planning
The planner places each count on the frames that can spin it and sees which frame is free after the next doff.
- Quality Control
The lab enters evenness, imperfection and strength readings per lot, and a lot below the buyer’s limit is held from packing.
- Stock Tracking and Alerts
Travellers, aprons and cots are issued to a frame, and the store sees which parts fall below the reorder level.
- Job Work Management
Yarn leaves on an outside process delivery note, and its returned weight is compared with the weight sent before the lot moves on.
- Order Management
A buyer’s order holds count, blend, cone weight and date, and shows how many kilograms are spun, packed and still owed.
- Batch and Serial Tracking
The lot printed on each bag label links back through the frames and the mixing plan to the bale lots 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 mill manager
See kilograms spun against order, yield by department, frames idle and lots held at the lab.
In planning
Place counts on frames, plan mixings from bale stock and watch which orders will miss their date.
In each department
Enter shift production and waste for the blow room, cards, combers, drawing, roving, ring and winding sections.
In the quality lab
Enter evenness, strength and neps against each lot, block any lot outside the buyer’s limit, and print the report that ships with the cones.
At the despatch desk
Pack against the order, print bag labels and release the packing list and invoice for the vehicle.
The numbers the owner asks for.
- Yield from fibre to cone by lot
- Waste by department and shift
- Ring frame running hours and stoppage causes
- Bale stock by lot and cover in days
- Lab results by count and lot
- Orders pending by count and date
- Outside process weight out against weight returned
Who this is built for.
- Cotton spinning mills making carded and combed counts
- Polyester and blended yarn spinners
- Mills with open-end and ring spinning units
- Spinners who send yarn out for doubling, gassing or dyeing
- Mills selling to weavers, knitters and trading houses
When it is not the right choice.
- A small twisting or reeling unit with one product can run on a stock register and a weighing book.
- A mill that also weaves and processes cloth will want the textile processor product for the wet side.
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
- Accounting export
- Weighbridge and bale scale
- Spindle and machine counters
- Barcode or label printer
- SMS or messaging for despatch notices
Questions owners ask before a demo.
Is this built for spinning or for any textile mill?
For spinning. Bale lots, mixing plans, frame counts and cone packing are the core. A mill that dyes or finishes cloth needs the processing product for that part.
Can it follow a bale to the cone?
Yes. The mixing plan names the bale lots, each count points to a plan, and the cone label shows the lot. A buyer’s claim on one cone leads back to its bales by the same chain.
Does it calculate yield?
Yes. Fibre issued, production by department and each waste head are entered, and the yield for the lot is shown from them. The waste heads are yours.
How are spindle breaks and machine stoppages recorded?
The supervisor or an operator logs a stop against the frame, card or winder with a cause. Counters from your machine supplier can feed it where they exist.
Can lab readings be printed for the buyer?
Yes. The readings recorded against a lot are printed as a report in the layout you use today. Which readings appear is agreed with your lab.
What about yarn sent out for doubling or gassing?
An outside process delivery note records weight out. When the yarn returns, the weight is booked and the difference is shown as shrinkage against that lot.
Can our existing orders and bale stock be loaded?
Yes. Bring your order book and the warehouse lot list; the planner walks the bays and corrects any lot that differs before the first shift.
Who owns the production data, and can it leave?
The mill does. Lots, readings and waste history can be exported to you, and the format is agreed before you sign.
How is it priced?
No figure is published. The proposal depends on how many departments and frames record, which users enter data, and how much old stock is migrated. A demonstration comes first.
Do we need it with only a few thousand spindles?
Perhaps not at first. One count and one buyer can be run from a good register. The need grows with blends, many counts and buyers who ask for a lot report.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
Related products.
See Yarn 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.
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- A reply within one business day
- Your details stay private
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