Why pipe manufacturers need dedicated pipe ERP software
A pipe plant buys resin by the tonne, mixes compound by the batch, runs extruders by kilograms per hour, and sells pipe by the length or the metre at a price per kg or per piece. Every size, wall thickness, pressure class and length is a separate item, and the margin depends on how close the weight per metre stays to the standard. Excel and an accounting package cannot hold this together.
Pipe ERP software ties these units together. DotOne, the platform we implement for PVC, CPVC and HDPE pipe makers, records compound batches, extruder runs, weight checks, scrap and regrind, and links them to dealer orders, GST invoicing and dispatch. Our plastic ERP software page covers moulding and film units that share many of the same needs.
The pipe process, stage by stage in the ERP
We map the ERP to how material moves through your lines, with input, output and loss recorded at each stage.
Resin and additive receipt
PVC resin, HDPE granules, calcium carbonate filler, stabilisers, lubricants, pigments and masterbatch are received with supplier, grade and lot. Bags and tonnes are converted automatically.
Compounding and mixing
Each hot and cold mixer batch is recorded from the formulation for that product family, with actual quantities of resin, filler and additives, and the compound is booked to a compound store.
Extrusion
Line runs record the extruder, die and sizing set, the size and class being run, output in kg and metres, and running hours. Weight per metre checks are captured during the run against the standard for that class.
Cutting, belling and inspection
Pipes are cut to length, socketed or belled, printed and inspected. Good output is booked by size, class and length, and rejected pipe goes to scrap.
Units: pieces, metres and kilograms
A dealer orders 6 metre lengths, the price list may be per kg or per piece, and production is measured in kg per hour. Each pipe item in the ERP carries its length and standard weight per metre, so stock can be shown in pieces, metres or kg from the same transaction.
When actual weight per metre runs above the standard, the plant is giving away material. The ERP compares actual weight from line checks with the standard for each class and shows the excess in kg and value by line and shift.
ISI classes, sizes and product variants
Pipe ranges multiply quickly. We build an item matrix so that masters stay manageable and stock reports stay readable.
- Size by outer diameter and wall thickness, with nominal and actual dimensions.
- Pressure class or SDR, for example agricultural, casing, SWR and plumbing ranges under the relevant IS standards.
- Lengths such as 3, 4 and 6 metres, plain or socketed.
- Brand and colour variants for units that run multiple brands.
- ISI and non-ISI product lines kept separate for stock, pricing and test records.
Test results for each lot, such as dimensions and hydraulic tests, are recorded through the quality management software module.
Scrap, regrind and weight control
Start-up scrap, trimmed ends, rejected pipe and lumps are a normal part of extrusion. The ERP books them as scrap by line, sends them to the pulverizer, and returns regrind to stock as a material with its own valuation. Regrind use in compound batches is recorded so that its share in each product stays within your limits.
Scrap reports show which line, die, size and shift produce the most waste, and how much material comes back as regrind compared with what is sold or lost.
Pipe costing, dealer sales and dispatch
Cost per kg and per piece is built from actual compound cost, power per kg on each line, labour, die changes and the loss from scrap and overweight. Management can compare it with realised dealer prices after discounts. See costing software for the methods.
Dealer price lists, discounts, schemes and credit limits sit in the ERP. Dispatch is planned by truck with a loading list of pieces and kg, and the GST e-invoice and e-way bill are generated from the same document. Pipes sent out for job work such as printing or belling move on job work challans tracked through job work software.
What is the best ERP for PVC pipe manufacturers?
Test any pipe ERP software on your own lines and ranges. Ask the vendor to show:
- Compound batches from formulation with actual resin and additive use.
- Line-wise output in kg, metres and pieces with running hours.
- Weight per metre checks against standard by class.
- Scrap to regrind flow with valuation.
- Item matrix for size, class, length and brand.
- Dealer schemes, credit control, e-invoice and e-way bill.
If you are moving from Tally, our Tally to ERP migration page explains how stock and dealer balances are carried over.
