Masterbatch & compounding
Masterbatch manufacturing ERP software
ERP for colour, white, black, additive and filler masterbatch manufacturers: customer-specific recipes with versions, batch-wise consumption of pigments and polymers, lot-wise QC results and traceability from raw material to bag.
What is masterbatch ERP software?
Masterbatch ERP software is business software built around how a compounding plant runs. Formezy keeps each customer's recipe with its versions, issues it with every batch, books the actual polymer, pigment, filler and additive weights against their lots, records QC results such as colour match and melt flow per lot, and links every bag dispatched back to its batch and raw materials.
Recipes are the product
In a masterbatch plant the recipe is the product. The same base polymer becomes hundreds of products through different pigments, fillers and additives, and many recipes are made for a single customer's shade or performance requirement. Recipes also change: a pigment supplier changes, a shade is adjusted, a cost is reduced.
Formezy keeps each recipe with its version history and approvals, so production always uses the approved version and you can see exactly which version made each lot.
From premix to packed bag
A typical route is weighing and premixing, compounding on a twin-screw extruder, pelletising, drying and packing. Formezy follows it step by step.
- Ingredients weighed against the recipe, with actual weights booked to their lots
- Extruder output, throughput and stoppages logged per batch and shift
- Lots created at packing with bag count and weight
- Start-up and changeover waste recorded by type
Quality results per lot
Every lot can carry its test results against the parameters set for that product and customer: colour match against the approved standard, melt flow index, moisture, dispersion, and ash content for filler grades. Lots that fail are held for correction or re-blending before they can be dispatched, and the results can be sent to the customer with the delivery.
Cost and traceability
Pigments and additives are expensive, and small over-dosing adds up. Because actual weights are booked against the recipe in every batch, Formezy shows the variance between standard and actual consumption and the real cost per kilogram of each product.
If a customer reports a shade problem, the lot traces back to the recipe version, the pigment and polymer lots used and the extruder run, and forward to every customer who received material from the same raw-material lots.
Shade development and lab trials
New shades and grades start as lab trials. Formezy records each trial recipe as a version, links the lab results and the customer's feedback to it, and turns the approved trial into the production recipe without retyping.
This keeps the history of how a shade was developed, so a repeat order or a similar shade for another customer starts from the right recipe rather than from memory.
What you get
What Formezy records in a masterbatch plant
Questions
Masterbatch ERP: common questions
Still have a question?
Talk to a plastic ERP specialist about your own plant and process route.
Can Formezy manage customer-specific masterbatch recipes?
Yes. Each recipe is kept with its version history and approval, can be linked to a customer and product, and is issued with every production batch.
Can it record colour match and melt flow results?
Yes. Test parameters are set per product and customer, and results such as colour match, melt flow index, moisture or ash content are recorded per lot.
How does it control pigment consumption?
The recipe is issued with each batch and the actual weights of pigments, polymers and additives are booked against their lots, so variance against the standard and cost per kilogram come from what was really used.
Does it handle filler and additive masterbatches as well as colour?
Yes. Colour, white, black, additive and filler masterbatches all run as recipes with their own test parameters.
Can lots be traced back to raw materials?
Yes. Each lot links to its recipe version, the raw-material lots used and the production run, and forward to the customers who received it.
Industries we serve
See it on your own recipes
Book a demo and we will walk through your plant, step by step.