Your existing ERP stays in place
We do not replace Logo, Mikro, Netsis or SAP. Accounting, e-invoicing and official processes continue in your current system; we build the plastics- and packaging-specific operational layer that works alongside it.
INDUSTRY SOFTWARE · PLASTICS AND PACKAGING MANUFACTURING
We make your plastics and packaging production real-time, from machine to dispatch.
In injection, extrusion, blow moulding and flexible packaging/flexo printing, scrap, downtime, shift output, mould maintenance and lot traceability are scattered across Excel, paper and the foreman's memory in most companies. We build the plastics- and packaging-specific operational software layer that works alongside your existing Logo, Mikro, Netsis or SAP system without replacing it.
9 Operational modules specific to plastics and packaging (OEE, traceability, scrap/regrind, mould CMMS...)
4+ Existing ERP integrations (Logo, Mikro, Netsis, SAP)
Lot End-to-end traceability from raw material lot to customer shipment
100% Source code and data are yours
Does this sound familiar?
The picture we see most often in plastics and packaging production.
If even one of the sentences below is yours, you are on the right page.
- Shop-floor data is collected on paper and in Excel: scrap, downtime, shift output and quality measurements are entered by hand; problems are noticed late, the data is wrong or missing, and there is no real-time machine visibility.
- The ERP and the floor are disconnected: Logo, Mikro or Netsis keeps accounting and stock, but the actual machine-level production, cycle counts, scrap and downtime data are entered either never or late and by hand; double records build up between the two worlds.
- The machine park is old and mixed: with injection, extrusion and blow moulding machines of different makes, and machines without EUROMAP 63/77 or OPC UA support, automatic data capture and OEE cannot be established.
- Scrap and regrind cannot be traced: which work centre, machine, operator or lot produced how much scrap, and what share of regrind went back into the recipe, is unknown; raw material cost and quality risk go uncontrolled.
- Mould and machine maintenance is reactive: preventive maintenance plans, mould cycle counters and spare parts stock mostly live in Excel or in people's heads; unplanned downtime and mould failures hit production.
- Lot/batch traceability is weak: in food-contact packaging, end-to-end traceability from raw material lot to finished product and shipment runs on manual files, creating risk in Food Contact Communiqué (2019/44) inspections and in recalls.
- Recipe, colour and masterbatch management is not standardised: dosing, colour changes and recipe revisions go unrecorded; colour and dimensional drift and inconsistency in customer-specific production follow.
- In flexible packaging/flexo printing, estimating depends on experience: when cylinder/anilox, layer and lamination counts, set-up waste and linear-metre calculations are done without an MIS, quotes and costs come out wrong.
- The chemical regulation load is scattered: raw material safety data sheets (SDS), KKDIK (Türkiye's REACH) compliance and labelling live in folders and Excel; keeping them current and delivering them to customers cannot be tracked.
- The systems sit as islands: the ERP separate, production tracking separate, quality in Excel, maintenance in a notebook; the same order, machine and product data is duplicated by hand in several places, creating inconsistency and double entry.
The sector's software landscape today
Which software do plastics and packaging producers use today, and where does it get stuck?
We lay out the industry's current picture as it is: real tools, real limits. The custom software opportunity begins exactly where these tools end.
| Layer | Software in use today | The gap it leaves |
|---|---|---|
| ERP / accounting (the common base) | Logo Netsis 3 (Production, Capacity, MRP and Machine Maintenance modules), Logo Tiger/GO, Mikro (Jump/Fly), SAP Business One and, at larger scale, SAP ECC/S4, ETA, DIA, Uyumsoft Liox ERP, Nebim V3 | Covers invoicing, accounts, accounting, stock cards, purchasing, sales orders and basic recipes/costing well. Among Gaziantep SMEs the core is usually Logo Netsis and Mikro, and among mid-to-large exporters SAP Business One. Machine-level actual production, OEE, scrap/regrind, mould maintenance and lot traceability are covered by these modules superficially or not at all; the gap is closed with Excel and paper. |
| Sector-specific ERP/MES (plastic injection & production tracking) | ERPIS ProINJECTION IMS (injection/blow moulding/extrusion/packing MES), A Yazılım Plastik Enjeksiyon Üretim Programı, True ERP Plastik, Aaro (plastics/packaging MRP), the Login ERP plastics & packaging package, Tilcomp Plastik ve Ambalaj ERP, PDS Star Üretim Takip | Aims to cover work orders, machine-level production, scrap/regrind tracking, recipe and raw material consumption and MRP. Depth varies from product to product; most are positioned to integrate with Logo/Mikro but struggle to fully cover mixed processes such as injection + flexo printing + lamination, and automatic data capture from an old machine park. |
| Flexible packaging & print management (MIS/ERP) | Sistrade MIS|ERP (flexible packaging, labels, flexo/lamination/extrusion; the Sentez Ambalaj reference in Türkiye), global counterparts CERM and EFI Radius; Esko ArtPro in prepress/colour management | Strong in quoting/estimating (cylinder/anilox, layer counts, set-up times, linear metres/waste), work orders, print planning and colour/graphics process tracking. It is the core for companies doing flexo printing + lamination, but it is positioned for mid-to-large scale and budgets; it is rarely found in small and mid-sized packaging firms, where estimating is left to experience. |
| Maintenance management (CMMS) and OEE | Bakım724 (a local CMMS for mould/press/injection machine breakdowns and periodic maintenance), the Logo Netsis Machine Maintenance module, Toku CMMS + OEE, Festo CMMS, the maintenance and OEE components on the MES side | Targets preventive maintenance for moulds and injection machines, breakdown/work orders, spare parts stock and OEE (Availability × Performance × Quality) tracking. In most SMEs maintenance still runs on Excel and paper; automatic maintenance triggers tied to mould cycle counters, and CMMS adoption generally, are only now spreading through the sector. |
| Machine connectivity / Industry 4.0 data capture | EUROMAP 63 (file-based), EUROMAP 77 / OPC UA 40077 (injection machines), middleware such as OPC Router, Mikrostar MES, Semi Otomasyon, APIOT field solutions | Enables real-time transfer of cycle counts, downtime, alarms and process parameters from injection machines to the MES. EUROMAP 77/63 are machine-builder-backed standards; in practice, because of old machine parks and brand mix, floor integration remains incomplete in most companies and has to be completed with counters and sensors. |
| Quality / SPC and regulatory-chemical management | On the quality side mostly Excel + paper forms and ISO 9001 documentation; in digitalised plants, Insize digital measurement infrastructure and PaperWork digital forms; on the chemical/SDS side Lisam, Doruk Chemical Safety (KKDIK, SDS, CLP); on the lab side, local LIMS such as LotusLab | Covers incoming quality, in-process control measurements and SPC; in food-contact packaging, raw material SDS management, KKDIK registration and traceability files. Global LIMS (LabWare, Thermo SampleManager) is rare in plastics, appearing mostly in chemicals and pharma; in plastics SMEs quality is still largely manual. |
| Warehouse / dosing / floor automation (the de facto tools) | Logo WMS, Netsis WMS, Mikro WMS (barcode/handheld terminals); Hastek colour and raw material dosing systems; IMC and EGR regrind/drying/loading equipment control; and the still-ubiquitous Excel, WhatsApp and paper forms | Covers rack stock, barcoded goods receipt/dispatch, silo and colour/masterbatch dosing and in-line regrind feeding. A WMS usually exists only in the large companies; in SMEs, stock still runs on the ERP stock module plus manual counts, and production and scrap tracking runs, in practice, on Excel and paper. That is where the custom software opportunity starts. |
Our approach
An operational layer that digitalises the floor in real time without replacing your ERP.
We keep your existing systems and build a plastics- and packaging-specific software layer on top that gathers machine data, traceability, scrap/regrind and maintenance processes into a single flow.
Data capture from the floor and the machines
Shift output, downtime reasons and scrap are entered where the work happens, on tablets and touch terminals; cycles and downtime are captured automatically — directly on machines with EUROMAP 77/OPC UA support, via counters and sensors on older ones.
Real-time OEE and downtime analysis
Machine-level OEE across availability, performance and quality; downtime reasons, shift efficiency and unplanned downtime trends are visible live. You see where the loss occurs without waiting for the end-of-day report.
End-to-end lot/batch traceability
Raw material lot, recipe/dosing, machine/mould/shift, finished product batch and shipment are linked under a single QR code/batch number. Tracking and simulation ready for food-contact regulation and recall scenarios.
Scrap, regrind and mould maintenance
We measure scrap by machine/operator/work order and calculate the regrind blend ratio in the recipe and its cost impact; preventive maintenance triggered by mould cycle counters, with mould life and spare parts tracking.
Management board and estimating on one screen
OEE, scrap trends, order-deadline status, machine loading and cost KPIs on a single screen for the owner; a smart quoting engine that standardises cylinder/anilox, layer and linear-metre calculations for flexible packaging/flexo.
The systems we build
The right system for every layer of plastics and packaging production.
You do not have to build everything at once; we start with the process that hurts most, with the module you need.
MES
Shop-Floor Data Capture & Production Tracking
Work-order-based shift output, downtime reason and scrap entry; the core module, collected on the floor via tablets and touch terminals, that digitalises the paper production log. You see the state of production in real time.
Detailed page → IoTMachine Connectivity & OEE
Cycle, downtime and alarm capture — directly on machines with EUROMAP 77/OPC UA support, via counters and sensors on older ones; real-time machine-level OEE. Data in a single language from a brand-mixed machine park.
Detailed page → QR
Lot/Batch Traceability Backbone
Forward-backward tracing under a single QR code from raw material lot to recipe, machine/mould/shift, finished product batch and shipment, plus recall simulation. An audit-ready file for Food Contact Communiqué inspections.
MES
CMMS Scrap & Regrind Cost Module
A module that measures scrap by machine/operator/work order and calculates the regrind blend ratio in the recipe and its raw material cost impact. Produces the in-line regrind savings business case in numbers.
Mould-Focused Maintenance Management
Preventive maintenance triggered by mould cycle counters, mould life and location tracking, spare parts stock and injection machine breakdown management. A field application that complements the Logo Netsis Machine Maintenance module.
Detailed page → MIS
Flexible Packaging/Flexo Estimating & Print Planning
A quoting engine and print scheduling that standardise cylinder/anilox, layer and lamination, set-up waste and linear-metre calculations. An SME-scale alternative to expensive MIS platforms such as Sistrade and CERM.
QMS
BI Digital Quality, SPC & Regulation
Digital quality control forms and SPC, raw material SDS and KKDIK document management, ISO 9001 record automation. Audit- and customer-ready file generation; paper forms disappear.
Management & Mobile Owner Panel
Reporting that combines your existing ERP/MES data to show OEE, scrap trends, order-deadline status, machine loading and cost KPIs on a single screen. Live visibility on the floor and on the phone.
Detailed page → APIExisting ERP Integration
Two-way data flow with Logo, Mikro, Netsis and SAP; orders, stock, production confirmations and scrap/cost synchronised on a single master record. The middle layer that ends double entry between the floor and accounting.
Detailed page → APIE-Export & Customer Portal
For exporting plastics and packaging firms: customer-specific labels and technical data sheets, shipment and container tracking, and a B2B portal (samples, orders, batch status). End-to-end visibility for your external customers.
Detailed page → Integration with your existing ERP
Digitalise without throwing your systems away.
You may be using Logo, Mikro, Netsis, SAP or another ERP; you do not have to replace it. Pan Innovation House builds the plastics- and packaging-specific operational layer that works alongside those systems. Accounting and official processes stay in your existing ERP, while machine data/OEE, scrap and regrind, lot traceability, mould maintenance and flexible packaging estimating are managed on a single master record. Orders, stock and production confirmations sync both ways between the two systems, and double data entry ends.
Our integration approach →- You do not have to replace Logo, Mikro, Netsis, SAP or any other ERP.
- Accounting, e-invoicing and official processes stay in your existing ERP.
- Machine data/OEE, scrap/regrind, lot traceability, mould maintenance and estimating are managed in the custom operational software.
- Orders, stock cards, products and production confirmations are held in a single master record, synchronised both ways with the ERP.
- Not a one-off migration; continuous, automatic and controlled integration.
Outcomes
What changes in plastics and packaging production once it digitalises?
- Machine-level real-time OEE and downtime reason visibility
- Automatic production data even from an old, brand-mixed machine park
- End-to-end lot/batch traceability from raw material lot to customer
- The affected batch scope in seconds during recalls and food-contact inspections
- Scrap measured by machine/operator/work order and regrind cost brought under control
- Less unplanned downtime and fewer mould failures through preventive maintenance tied to mould cycle counters
- Consistent, customer-specific production with versioned recipes, colours and masterbatch
- Flexible packaging/flexo quotes produced fast and error-free with standardised estimating
- Lower regulatory and audit risk by tracking current SDS and KKDIK documents
- Excel and paper islands removed, double data entry ended
Process
A realistic five-stage path that begins with discovery.
- 01
Initial meeting
1 weekWe listen to your needs, your current ERP, your machine park and your production mode (injection, extrusion, blow moulding, flexo). We clarify expectations and draw the right scope together. No obligation.
- 02
On-site survey and process analysis
1-2 weeksWe come to the plant and observe the machine park, shift flow, scrap and regrind process, mould maintenance, warehouse and the printing/lamination line in place. We map the machines' EUROMAP/OPC UA status and your current Excel setup.
- 03
Digital transformation roadmap
1 weekWe present a clear roadmap of which module goes live first, ranked by benefit and priority. The fastest gains usually come from shop-floor data capture, OEE and scrap tracking; a phased plan that fits your machine park.
- 04
Module-based software development
By moduleStarting with the process that hurts most, we develop the modules one by one and test them in the shift. We build the machine connections and the ERP integration, with visible progress at every step; no surprises.
- 05
Go-live, training and support
OngoingWe train the production, quality, maintenance and dispatch teams, take the system live and stay at your side. As new machines, new moulds and new needs appear, the software grows with you.
Why Pan Innovation House?
Not a software vendor, but a digital transformation team that knows the shop floor.
A local team that knows the Gaziantep and organised industrial zone (OSB) plastics-packaging industry
We know how injection, extrusion, blow moulding and flexible packaging production works — the reality of shifts and the pressure of scrap. We are no strangers to the OSB floor and its realities.
A software approach that understands the floor and the machine park
We design by talking through machines, moulds, shifts, scrap and the printing line. We know how to capture data from an old machine park; we fit the software to the floor, not the floor to the software.
Not an off-the-shelf package — a solution built for your business
We do not force you into a template. An injection producer and a flexo printing/lamination firm have different needs; the software is built around your processes, and there is no paying for modules you do not use.
Digitalisation without replacing the ERP
We protect your existing Logo/Mikro/Netsis/SAP investment and build on top of it. We do not put you through a risky, expensive and drawn-out ERP migration; we add the layer that closes the shop-floor gap.
A view that sees cost and traceability as one whole
Not just production tracking: we treat OEE, scrap/regrind cost, lot traceability, mould maintenance and management reporting as a single whole.
A realistic project model that starts with an on-site survey
We come, see and listen first. We measure before we promise; we offer a workable plan rather than inflated claims. 100% of the source code and data stays with you.
Frequently asked questions
Common questions about Plastics and Packaging Manufacturing software.
Do we need to replace our existing Logo / Mikro / Netsis / SAP system?
No. Your existing ERP and accounting system stays in place. We build a plastics- and packaging-specific layer beside it that manages shop-floor data capture, OEE, scrap/regrind, lot traceability, mould maintenance and estimating, and where needed we provide two-way data integration between the two systems.
Our machines are old and from different makes; can we still collect data automatically?
Yes. We connect directly to injection machines that support EUROMAP 77 / OPC UA; on older machines without these standards we add cycle counters and sensors to capture cycle, downtime and production data. Turning a mixed-brand park into real-time OEE in a single language is the core of the job.
Does scrap and regrind tracking deliver concrete savings?
Yes — that is exactly what the module is for. We measure scrap by machine, operator and work order, and calculate the regrind blend ratio in the recipe and its impact on raw material cost. That lets us produce the business case for in-line regrind savings in numbers, sharp enough to use in grant applications such as KOSGEB.
How do you provide lot traceability in food-contact packaging?
We link the raw material lot, recipe/dosing, machine/mould/shift, finished product batch and shipment under a single QR code/batch number. We provide a simulation that shows in seconds which batches went to which customer in a complaint or recall, and audit-ready file generation for Food Contact Communiqué (2019/44) inspections.
Can we manage mould maintenance too?
Yes. We set up preventive maintenance triggered by mould cycle counters, mould life and location tracking, spare parts stock and injection machine breakdown/work order management. This module complements the Logo Netsis Machine Maintenance module if you use it; if you do not, it works as a standalone CMMS on the floor.
Is an MIS such as Sistrade essential for flexible packaging/flexo estimating?
It is not. MIS platforms such as Sistrade and CERM are powerful but positioned for mid-to-large scale and budgets. We build an SME-scale quoting engine and print scheduling that standardise cylinder/anilox, layer and lamination, set-up waste and linear-metre calculations, removing quoting and costing errors.
How long does the project take?
It would be wrong to give a single figure; it depends on the scope, the number of modules and the machine park. That is why we work module by module: we usually start with shop-floor data capture, OEE and scrap tracking, which deliver the fastest gains, show the first benefit quickly, and then grow the system in stages. We share a firm timeline after the survey.
Do you also serve plastics and packaging producers outside Gaziantep?
Yes. We are based in Gaziantep and know the OSB plastics-packaging industry closely, but we also serve producers in the surrounding provinces and across Türkiye. We plan the on-site survey and the project programme together.
Let us start together
Let us see your production first — then let's talk.
In the on-site survey we examine your machine park, shift flow, scrap and regrind process, mould maintenance and printing/lamination line in place, and together we determine which module will bring you the fastest benefit. No obligation.
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