Custom ERP for Flexible Plastic Packaging Manufacturing

Client : Chetan Plastic

Industry : Manufacturing / Flexible Packaging (Pouches & Laminates)

About Chetan Plastic

Chetan Plastic is a specialized manufacturer in the flexible plastic packaging industry, producing highly customized, multi-layered laminates and pouches for diverse sectors, including leading FMCG and nutrition brands. Flexible packaging is fundamentally complex; costing and production rely on intricate calculations involving thickness (MIC), multiple material layers (PET, MET PET, Foil, Poly), and dynamic conversions between weight (Kg), pieces, and rolls. They required an advanced, custom-built ERP ecosystem capable of managing this hyper-specific engineering, from complex quoting to multi-stage manufacturing and highly granular dispatch logistics.

Core Business Challenges

Complex Estimations & Quotations

Standard ERP quoting could not handle their requirements. Pricing a pouch involves calculating open sizes, wastage percentages, layer-wise MICs, printing charges, and converting rates dynamically from Per/Kg to Per/Pcs.

Multi-Layer BOMs & Sourcing

A single product might require different layers sourced from multiple specialized vendors before arriving at the facility for final lamination and cutting.

Dynamic Quantity Conversions

Tracking inventory and manufacturing yield required continuous mathematical conversions (e.g., 800 Kg ➔ 268 pcs/kg ➔ Weight per 1000 pcs) which standard Odoo Inventory does not natively support.

Intricate Dispatch & Packing Tracking

Generating delivery notes required extremely detailed parcel-level tracking, including gross weights, tare weights, net weights, and exact piece counts per packet, alongside partial delivery status tracking.

Solution Focus

Custom Price Calculator Engine

Multi-Layer Material Structuring

Advanced Roll-to-Pouch Conversions

Complex Packing List Generation

Multi-Vendor Sourcing

The Proposed Solution & Process Workflow

CandidRoot completely overhauled Odoo's Sales, Inventory, and Manufacturing modules, creating a highly tailored ERP vertical for the flexible packaging industry.

Industry-Specific CRM & Quotation Engineering

Custom Pipeline: Leads flow through a specialized pipeline tracking every stage up to PI Approval and Purchase Pending.
Advanced Costing Engine: Built a powerful "Price Calculator" directly inside the quotation module. Sales reps input the Pouch Type, Width, Height, Material Layers, and Wastage %. The system automatically calculates the Open Size, MIC, Conversion Ratio, and precise Rate/Kg vs. Rate/Pcs, including printing and lamination charges.

Material Structure & Procurement Workflows

Layer-wise Definition: Products are defined by their structural layers (e.g., PET + MET PET + LDNat HM Poly).
Multi-Vendor Sourcing: Based on the approved PI, the system triggers targeted Purchase Requirements, handling complex procurement where different layers are sourced from different vendors.

Roll-to-Pouch Manufacturing Integration

Quotations seamlessly generate deeply linked Manufacturing Orders (MO).
The production floor manages a multi-stage routing workflow, automating continuous mathematical quantity conversions (tracking the yield of semi-finished rolls in Kg and converting the final output into discrete Pouch Pieces).

Custom Repair & Maintenance Management

Developed a completely custom Repair Module to handle dies, printing cylinders, and machine parts.
The workflow tracks components moving to external Repair Vendors, fully integrated with stock movements to ensure accurate valuation and location tracking.

Automated Summary Sheets & Complex Packing Lists

Granular Packing Details: Engineered a custom Packing Details and Delivery Note report. The system tracks every single dispatch at the parcel level, recording Gross Weight (Gr. Wt.), Tare Weight (Tr. Wt.), and Net Weight per parcel.
Packet & Piece Tracking For discrete items, the packing list automatically calculates the number of Packets (Pkts), Pieces (Pcs), Total Pieces (T. Pcs), and their corresponding weight in Kgs.
Part Delivery Summary: The system provides real-time tracking of partial shipments, generating a summary that compares the original Order Quantity against the Delivered Quantity to calculate the exact Balance Order Quantity (in both KGS and PCS) and dynamically updates the Order Status (e.g., Pending).

Business Impact & Value Delivered

Zero-Error Cost Estimations

The custom Price Calculator eradicated manual spreadsheet errors, allowing the sales team to generate highly complex, multi-layered packaging quotes instantly and accurately.

Flawless Dispatch Logistics

The custom packing list engine eliminated manual dispatch errors, providing both the warehouse team and the client with absolute clarity on parcel weights, piece counts, and outstanding delivery balances.

Accurate Yield & Inventory Valuation

By automating Kg-to-Pieces and Roll-to-Pouch conversions, Chetan Plastic gained 100% accuracy in raw material consumption, wastage tracking, and finished goods inventory valuation.

Minimized Tooling Downtime

The integrated Repair Management system provided total visibility over external maintenance, preventing delays in the printing and cutting phases due to missing or damaged tooling.

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