Film Manufacturing ERP- Enterprise ERP for High Volume Blown & Cast Film Manufacturers
Orchestrate multi-plant operations, integrate SCADA for real-time deckle matching, and ensure global export compliance with Microsoft Dynamics 365.
Streamline your workflow and reduce waste
Film Manufacturing Samadhan ERP offers a tailored solution to help you minimize waste and maximize efficiency in your blown and cast film manufacturing process. By focusing on deckle optimization and automated calculations, our ERP system ensures you get the most out of your materials and machinery.
Powered by Microsoft Dynamics 365
Our specialized Film Manufacturing ERP is more than just a software platform; it is an industry-specific accelerator built on the robust foundation of Microsoft Dynamics 365 Business Central. This strategic integration offers manufacturers the best of both worlds: the global stability, enterprise-grade security, and cloud scalability of the Microsoft ecosystem, combined with Samadhan’s decades of deep domain expertise in the flexible packaging and plastic extrusion sectors.
Our solution addresses this with advanced Deckle Matching logic, which automatically calculates and suggests the optimal combination of customer orders to run simultaneously. This eliminates guesswork, ensuring your extruder runs at maximum capacity with minimal scrap generation.
Strengthening Operational Control in Film Manufacturing ⇒
Machine Integration (IoT)
The ERP does integration with machines like Windmöller & Hölscher, removing the need for manual work. This results in significant reductions in trim waste and boosts your profitability.
Primary & Secondary Slitting
Primary & Secondary Slitting is planned via Deckle Optimization & facilitate real-time reel tracking based on jumbo size, deckle combinations, and production sets.
Real-time Updates
Facilitate real-time tracking based on jumbo size, deckle combinations, and production sets. Integrate bar code/QR code systems for efficient identification and tracking of jumbo and slitted reels.
FAQs
Everything you need to know about ERP solutions for Film Manufacturing industry
Does the solution support bi-directional integration with Extrusion lines (e.g, Reifenhauser) for automated production booking?
Yes. Samadhan ERP is designed to integrate with PLC/SCADA systems via IoT connectors. This allows for the automated capture of machine run-time, actual consumption, and output quantity directly into the ERP, eliminating manual data entry errors and providing real-time OEE (Overall Equipment Effectiveness) monitoring.
How does the system handle "Regrind" or "Repro" material costing when mixed with Virgin Resin?
The system manages complex Bills of Material (BOM) that account for regrind percentages. It adjusts the weighted average cost of the finished film in real-time based on the ratio of virgin-to-repro material used, ensuring your inventory valuation and profit margins per batch are accurate, even when recycling internal waste.
Can the Deckle Matching Engine look across multiple Sales Orders to optimize production planning?
Absolutely. The Advanced Planning & Scheduling (APS) module analyzes your entire backlog of open sales orders. It suggests the optimal combination of slitted widths to fit your master roll width, minimizing trim waste and reducing the frequency of machine changeovers.
We export to Europe and the US. How does the system handle Forward and Backward Traceability for BRCGS/FDA audits?
The system enforces strict Lot/Batch tracking from raw material receipt to finished goods dispatch. In the event of a recall or audit, you can generate a genealogy report in seconds, tracing a specific finished roll back to the specific resin batch, machine operator, and shift time, ensuring 100% compliance with global standards.
Does the ERP support Quality Control (QC) "Holds" that physically block dispatch at the weighbridge?
Yes. The system integrates QC parameters (GSM, Micron, Opacity, COF) into the workflow. If a Jumbo or Slitted roll fails a specific test, the system automatically flags the Batch ID as “Quarantine.” This prevents the dispatch team from generating a packing list or gate pass for that specific roll until authorized.
We operate multiple manufacturing plants. Can Samadhan ERP handle Inter-Company Transactions and centralized procurement?
Built on Microsoft Dynamics 365, the solution is natively multi-entity. It allows you to manage multiple plant locations within a single database. You can execute centralized purchasing of Resin to negotiate better rates, transfer stock between plants with automated inter-company invoicing, and view consolidated financial reports instantly.
How does the system handle the conversion between "Kg," "Meters," and "Rolls" across different production stages?
We understand that you buy Resin in Kgs, produce Jumbos in Kgs/Meters, and sell Slitted rolls in Numbers or Meters. The ERP handles “Dual Unit of Measure” (UOM) throughout the lifecycle, automatically calculating conversion based on specific gravity, GSM, and width, ensuring inventory accuracy across all metrics.
Can the system manage "Toll Manufacturing" (Job Work) processes where we send films for external metalizing or coating?
Yes. The system tracks inventory sent to subcontractors as “Stock lying with Third Party.” It manages the challans, tracks the aging of stock at the vendor’s location, and accounts for the value addition (coating/metalizing cost) upon receipt of the finished material, ensuring accurate landed costs.
What is your typical data migration strategy for companies moving from SAP B1 or Legacy Custom ERPs?
We utilize a structured migration methodology designed for high-volume manufacturers. We do not just move data; we clean it. We focus on master data sanitization (Item Masters, BOMs, Customer Ledgers) and typically run a “Parallel Run” phase to ensure the financial numbers in the new ERP match your legacy system down to the decimal before Go-Live.
Is the solution scalable for high-volume transactions (e.g., 500+ invoices/day)?
Leveraging the cloud power of Microsoft Dynamics 365 Business Central, the system is architected for high concurrency. It easily handles high transaction volumes across sales, dispatch, and production without performance lag, making it suitable for enterprises with turnover exceeding ₹100 Cr – ₹500 Cr.
Reasons to choose Film Manufacturing Samadhan ERP
Why choose Samadhan ERP for your blown and cast film manufacturing business?
Industry Expertise
We understand the unique challenges of the blown and cast film industry and have crafted a solution specifically for your needs.
Batch Consumption Management
The solution has the feature of batch consumption posting for the individual document and collective consumption posting for multiple jumbos.
Automated Yield Intelligence
Move beyond legacy reporting. Get predictive analytics on yield loss per micron, per shift, aligned with machine speed and downtime.
Scalable Solution
Whether you're a small operation or a large manufacturer, our ERP can scale with your business, growing alongside you.
Manage trim loss
The system automatically calculates expected jumbo weight based on linear meter and machine speed, optimizing material usage for primary and secondary slitting.
Curious about our Film Manufacturing ERP? Book a demo today!
With a demo you can understand our services better and then take an informed decision about your brand.
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