Resin, filler, stabiliser and masterbatch proportions sit in somebody’s head, so a batch varies with whoever mixed it.
PRODUCT 05 · PVC & PLASTIC EXTRUSION
PVC Manufacturing ERP
Compounding is a recipe, extrusion is a run, and scrap is money going back into the hopper. Genzerp tracks resin through to finished length, including the regrind most systems pretend does not exist.
14Connected modules
KgAnd metre, both
AIBuilt into reporting
PVC Manufacturing ERPLive view
RUNNING
01
Compound defined
02
Batch mixed
03
Extrusion run
04
QC checked
05
Scrap & regrind
06
Packed & costed
Compound defined
SOUND FAMILIAR?
The four things that slow this business down.
Startup scrap and rejected lengths go back into the mix untracked, so material consumption never reconciles.
Production is recorded in kilograms and sold in metres, and the conversion between the two is a guess that differs per product.
A line stopping for a die change or a breakdown is obvious at the time and invisible by month end, so nobody knows what it cost.
THE WORKING FLOW
How a batch actually moves
This is the path a compound takes through Genzerp, from the recipe to the finished length, with the material balance closing at the end.
The compound is stored as a recipe of percentages, so a change in resin or filler re-calculates the whole mix.
Resin, filler and additives are issued against the batch, including the regrind going back in, so consumption reconciles.
The run is booked against a line and die, with output recorded in both weight and length.
Thickness, width and finish are checked against the specification before a run is accepted.
Startup scrap and rejects are weighed back in as regrind, so nothing drops out of the material balance.
Finished lengths are packed and the batch closes with its real material, scrap and machine cost attached.
GENZAI
Ask it about your material
GenzAI reads the data this product already creates. You ask in plain language; it answers with the numbers behind it.
GenzAIConnected to your production data
LIVE
Where is my material going?
It closes every batch’s input weight against its output and regrind, then ranks the runs where the balance did not close.
Batches56
Balance off over 2%7
Worst run5.8%
Which line is costing me the most downtime?
It totals logged stoppages by line and reason, and sets the production time lost against each one.
Lines4
Stoppages23
Hours lost61
What does this product really cost per metre?
It closes resin, additive, scrap and machine time per batch and gives cost per metre by product and die, not one blended rate.
Products29
Batches closed56
Spread9%
Ask your business anything…
➤
WHAT YOU GET
What is inside the product
Everything below runs on the same connected core, so the recipe, the line and the invoice all read from one set of numbers.
Percentage-based compound definitions, so a batch of any size re-calculates resin, filler and additive quantities on its own.
Track runs by line and die, with output recorded in both kilograms and metres against the same batch.
Weigh scrap back in as regrind against the batch it came from, so material consumption actually reconciles.
Raw material stock by grade and lot, with movements, low-stock alerts and supplier traceability.
Record thickness, width and finish checks against the specification before a run can be accepted.
Material, scrap and machine time close against the batch, giving cost both ways so quoting is not guesswork.
Log line stoppages with reasons, so the cost of a die change or a breakdown becomes measurable.
Orders reserve finished lengths, and dispatch documents carry batch, length and weight without re-entry.
Invoices, payments, ledgers and GST-ready documents built on the same data as production — no second entry, no month-end reconciliation.
Leads, sources, statuses, follow-ups and meetings, so an enquiry and the order it turns into live in one place.
Positions, resumes, onboarding, leave requests and exits, with roles and permissions set per user and per module.
Ask for the numbers in plain language. Order predictions, P&L, consistency, performance and productivity reports come as standard.
WHY IT FITS
Built around the material balance
In extrusion the question is always the same: how many kilos went in, how many metres came out, and where did the difference go. A general-purpose system cannot answer the third part, because it has nowhere to put regrind.
Regrind is tracked, not ignoredScrap is weighed back in against the batch that produced it, so the material balance closes instead of quietly drifting.
Kilograms and metres are both realOutput is recorded in weight and in length, with the conversion held per product, so stock and quoting both work from real figures.
The compound is a percentage recipeChange the batch size or a raw material and the whole mix re-calculates, rather than being re-typed by whoever is on shift.
Downtime has a cost attachedLine stoppages are logged with reasons, so the real cost of a die change shows up against the batch it delayed.
BEFORE YOU ASK
Questions we get every time.
Can it handle compound recipes as percentages?
Yes. Compounds are stored as percentages, so changing the batch size or a raw material re-calculates the whole mix rather than needing a new recipe.
How is scrap and regrind handled?
Scrap is weighed back in as regrind against the batch that produced it, so material consumption reconciles instead of drifting over the year.
We produce by weight but sell by length. Does that work?
Yes. Output is recorded in both, with the conversion held per product, so stock and quoting both use real numbers.
Can we track machine downtime?
Yes. Stoppages are logged per line with reasons, so lost time is measurable and attributable rather than just remembered.
Will it work alongside our existing accounting software?
Yes. Genzerp covers production, stock, quality and costing, and can pass the resulting documents to the package you already use.
Can we run it on our own server?
Yes. It runs on our cloud or on your own server, whichever your IT policy requires.
THE REST OF THE RANGE
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Pharmacy stock, purchase, billing and compliance.
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See it running on your numbers.
Bring one real product and one real batch. We will show you exactly how it would look in Genzerp — not a generic demo.