Machine plans that ignore the mould
Jobs are planned from the mould's running cavities and cycle time, so expected output per shift is known before the job starts.
Injection, blow and roto molding
Plastic Molding ERP software
Built for plastic molding plants, from resin and masterbatch receipt through drying, blending, mould setup, molding, trimming and testing to packing, with machine planning by mould cavity and cycle time, mould shot counts and regrind control.
Quick answer
What is plastic molding ERP?
Plastic molding ERP is business software built around how a molding shop runs. Formezy plans machines by mould cavities and cycle time, records the resin, masterbatch and regrind used in each batch, counts shots and good parts per shift, tracks every mould's shot count and maintenance, and holds parts that fail inspection, so output, scrap and cost per part stay current.
Moulds maintained too late
Each mould's shot count builds up from production entries, and preventive maintenance falls due by shots, not by memory.
Regrind and rejects not counted
Runners, flash and rejects are weighed back to regrind stock, and the regrind percentage in each batch is recorded.
Segments
Built for every plastic molding segment
3 segments, each with its own shop-floor process flow.
Injection molding
Household items, caps and closures, containers, crates, pharma and engineering parts. Plan by cavity and cycle time, count shots per shift and track every mould.
See the 8-step flowBlow molding
Bottles, jerrycans, drums and containers made by extrusion, injection or stretch blow molding. Track blends, cavity output, leak testing and flash returned to regrind.
See the 7-step flow
Roto molding
Water tanks, large containers and hollow parts made from roto-grade polyethylene. Charge weights, oven cycles and tank weights recorded per piece.
See the 7-step flowShop-floor process flow
How Formezy runs a plastic molding plant
Choose a segment, then a step. Each one shows what happens on the shop floor, what Formezy records, and what changes as a result.
On the shop floor
Resin, masterbatch and inserts received and weighed
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Resin lot traced from day one
On the shop floor
Resin dried where needed and blended with masterbatch and regrind
In Formezy ERP
Blend recipe issued; virgin, regrind and masterbatch weights booked per batch
Production & Purchase moduleShop-floor impact
Regrind ratio on record
On the shop floor
Mould loaded and the machine set for the job
In Formezy ERP
Mould no., running cavities and setup time logged; mould change recorded
Machine Maintenance moduleShop-floor impact
Changeover time visible
On the shop floor
Parts molded shot by shot
In Formezy ERP
Shots, cycle time and stoppages captured per machine; mould shot count updated
IoT & Automation moduleShop-floor impact
Output vs. plan, live
On the shop floor
First-off and hourly checks for weight, dimensions, flash and short shots
Shop-floor impact
Defects caught at the machine
Quality gate. If it fails: correct the process and send rejects to regrind.
On the shop floor
Runners and sprues removed and ground
Shop-floor impact
Scrap weighed, not guessed
On the shop floor
Parts counted into bags, cartons or pallets
Shop-floor impact
Finished stock by batch
On the shop floor
Cartons loaded against the order
Shop-floor impact
No manual packing lists
Injection molding, step 1 of 8
Material receipt
On the shop floor
Resin, masterbatch and inserts received and weighed
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Resin lot traced from day one
On the shop floor
HDPE, PP or PET resin and masterbatch received and weighed
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Resin lot traced
On the shop floor
Virgin resin blended with masterbatch and regrind
Shop-floor impact
Blend recorded per batch
On the shop floor
Parisons or preforms blown into containers
Shop-floor impact
Output per machine, live
On the shop floor
Flash trimmed and containers weighed
Shop-floor impact
Weight drift spotted early
On the shop floor
Containers leak tested; samples checked for weight, wall and fit
Shop-floor impact
Leaking containers never ship
Quality gate. If it fails: reject to regrind.
On the shop floor
Containers printed or labelled
In Formezy ERP
Print or label job linked to the batch; consumables booked
Production & Purchase moduleShop-floor impact
Decoration cost per batch
On the shop floor
Containers bagged or palletised and loaded
Shop-floor impact
Order-wise dispatch
Blow molding, step 1 of 7
Resin receipt
On the shop floor
HDPE, PP or PET resin and masterbatch received and weighed
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Resin lot traced
On the shop floor
Roto-grade PE powder or granules and masterbatch received
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Material lot traced
On the shop floor
Granules ground to powder and coloured with UV-stabilised masterbatch
Shop-floor impact
Powder yield known
On the shop floor
Powder weighed into the mould for each product
Shop-floor impact
Material per tank known
On the shop floor
Mould heated in the oven while rotating biaxially
Shop-floor impact
Cycle data per piece
On the shop floor
Mould cooled and the part removed
Shop-floor impact
Output per arm, live
On the shop floor
Weight, wall thickness, finish and leaks checked
Shop-floor impact
Weak tanks never ship
Quality gate. If it fails: repair if allowed, otherwise scrap to regrind.
On the shop floor
Fittings and lids added, tanks labelled and loaded
Shop-floor impact
Every tank traceable
Roto molding, step 1 of 7
Material receipt
On the shop floor
Roto-grade PE powder or granules and masterbatch received
In Formezy ERP
GRN posts grade, supplier lot no. and weighbridge weight; bags labelled with a lot barcode
Weight Integration moduleShop-floor impact
Material lot traced
Dashed ring marks a quality gate, where failed material is held before it moves on.
Capabilities
What Formezy covers in plastic molding
Open an area to see what it covers.
Cavity-based planningOutput per shift from running cavities and cycle time.
Machine allocationJobs assigned to machines that suit the mould.
Mould masterCavities, cycle time, tonnage and part weight per mould.
Shot countsMould shot count built up from production entries.
Mould maintenancePreventive maintenance due by shots or date.
ChangeoversMould and colour changes logged with time taken.
Recipe managementResin, masterbatch and regrind percentages per part.
Shift-wise analysisOutput, rejects and stoppages per machine and shift.
Regrind controlRunners, flash and rejects returned to regrind stock.
WIP visibilityParts awaiting printing, assembly or packing.
Production costingMaterial, machine and labour cost per part.
First-off approvalFirst-off checks recorded before the run continues.
In-process checksWeight, dimensions and visual defects per hour.
Defect trackingRejects booked by defect type for root-cause analysis.
HoldsSuspect batches held until cleared.
Questions
Plastic Molding ERP: common questions
Still have a question?
Talk to a plastic ERP specialist about your own plant and process route.
Which plastic molding segments does Formezy support?
Formezy supports injection molding, blow molding and roto molding, each with its own process flow. Plants that combine segments run them in one system.
Does Formezy support injection, blow and roto molding?
Yes. Each has its own process flow, and plants running more than one molding process, or molding alongside extrusion, work in one system.
How does machine planning work for molding?
Each mould carries its cavities, cycle time and part weight. Planning uses the running cavities and cycle time to work out output per shift, so jobs are matched to suitable machines and delivery dates are realistic.
Can Formezy track mould shot counts?
Yes. Shots booked in production add to each mould's shot count, and preventive maintenance can fall due by shot count or by date, with the history kept against the mould.
How is regrind handled?
Runners, sprues, flash and rejects are weighed back to regrind stock, and blend recipes record the regrind percentage used in each batch, so its use is tracked and costed.
Can it record in-process quality checks?
Yes. First-off and periodic checks for weight, dimensions and visual defects are recorded per job, rejects are booked by defect type and suspect batches are held.
How is cost per part calculated?
Resin, masterbatch, regrind credit, machine time, labour and packing are booked against the job from actual consumption, giving cost per part and per kilogram.
Other industries
Ready to run your plastic molding plant on one system?
See Formezy configured around your own process route, from receipt to dispatch.