Continuous / reels
ERP for Paper Mills
Broke goes back into the pulper and has to be valued. Reel genealogy — which jumbo a sheet came from — is what makes a GSM complaint resolvable.
- Stages mapped
- 6
- Quality checks
- 4
- Wastage rules
- 3
- Compliance items
- 3
Your process
The stages, already mapped.
Pulping to finishing with reel genealogy. These are the stages the template ships with — machines and checks included. Yours will differ in detail; that is configuration, not development.
- 1
Pulping
Hydrapulp waste paper with contaminant removal
- Machines
- Hydrapulper
- Checked
- Freeness (CSF)
- 2
Stock preparation
Refine, clean, blend furnish with additives
- Machines
- Refiners, cleaners
- Checked
- Consistency, pH
- 3
Paper machine
Form, press and dry the sheet at target GSM
- Machines
- PM-1 (2.8 m deckle)
- Checked
- GSM scanner, moisture
- 4
Calendaring
Smoothness and caliper control
- Machines
- Calendar stack
- Checked
- Smoothness, caliper
- 5
Rewinding / sheeting
Rewind to customer reel sizes or sheets
- Machines
- Rewinder, sheeter
- Checked
- Reel width, dia
- 6
Packing
Wrap reels with core labels and weigh
- Machines
- Reel wrapper
- Checked
- Weight, label
What goes in
Waste paper, pulp, chemicals
What comes out
Reels & sheets by GSM
Kraft paper 80–200 GSM · Duplex board · Absorbent kraft
Who is it for
Not all paper mills work the same way.
The template is the same; what it has to answer for is not. Find the one that sounds like you — if none of them do, say so on the call and we will tell you honestly whether this is the right fit.
Paper & board mills
Reel-wise production, GSM and deckle-width planning.
Recycled-fibre mills
Waste-paper grades in, yield and reject percentages out.
Converters running bought-in reels
Sheeting and slitting costed against reel consumption.
MANUPRIME AI
Ask it about this floor, in your own words.
The AI reads the same records this template creates — so on a paper mill floor the questions it can actually answer are the ones you already ask at the morning meeting.
Questions it answers here
- “Why has machine efficiency moved this week?” — currently 89% in the demo data
- “Why has steam t/t paper moved this week?” — currently 1.9 in the demo data
- “Why has broke % moved this week?” — currently 7.5% in the demo data
- “Where is my wastage going?” — broke (recycled), trim, costed back to the batch that caused it
- “What am I short of in the next 14 days?” — with the covering purchase order drafted for approval
And what it is not allowed to do
It shows its working, or it does not answer
It drafts. A person releases
It sees only what the person asking can see
Quality
What quality control looks like here.
Checks that hold a dispatch, at the frequency this trade actually inspects.
| Parameter | Method | Frequency |
|---|---|---|
| GSM | Online scanner + lab | Continuous + per reel |
| Burst factor | Burst tester | Per reel set |
| Moisture | Online + oven | Continuous |
| Cobb (absorbency) | Cobb tester | Per grade run |
Wastage and recovery
The part generic ERPs get wrong.
Most systems can only write material off. In this trade that is the difference between a costing you believe and one you argue with.
Rules that ship with this template
- Broke (wet/dry) recycled to pulper with meter
- Trim standard by deckle utilisation
- Reel rejects downgraded with reason code
What drives your cost per unit
- Waste-paper furnish mix cost
- Steam & power per tonne
- Machine deckle utilisation %
In short:Broke (recycled), trim.
Compliance
What this trade has to prove.
Configured, not bolted on afterwards — the records come out of the same transactions your floor is already entering.
On the dashboard
The numbers this plant is judged on.
Sample figures from the demo, so you can see the shape of what you would be looking at every morning.
- Machine efficiency
- 89%
- Steam T/T paper
- 1.9
- Broke %
- 7.5%
Illustrative values from the demo dataset, not a customer's figures.
Questions
Questions we get asked first.
Is broke recovered into stock?
Yes, as a recovered furnish with its own rate, dosed back into stock preparation within a permitted percentage.
Can we trace a sheet back to its jumbo reel?
Rewinding and sheeting keep the parent reel on every child, so a GSM or moisture complaint resolves to a specific jumbo and the run that made it.
How are GSM and moisture recorded?
As inspection parameters on the reel with tolerances, sampled at the machine, and the reel label carries the measured values.
See it running with Paper Industries data.
The demo opens with this trade's materials, machines, checks and reports already in place. No signup, nothing to install.