Omeecron Plastic Manufacturing ERP
Built for Indian injection-moulding, blow-moulding & extrusion units. Per-mould cycle-time costing, cavity-wise yield, virgin/regrind ratio control, live polymer-price quoting, and EPR / CPCB compliance built in. Stop letting your worst mould subsidise your best customer.
Where the day-to-day really hurts
Real pain we’ve seen on Indian factory floors — and how the system fixes each one.
Per-mould profitability is invisible. You think Customer X is your best account but their mould runs 35% over cycle-spec — they're your worst.
Per-mould cycle-time costing (actual × spec × scrap × operator) surfaces loss-leader products before they bleed the P&L. Re-quote or fire the customer with data.
A 12-cavity mould has one bad cavity. You waste 8% of every shot for weeks before someone notices. Customer rejects come back; you blame "the powder".
Cavity-wise good/reject capture from PLC OR manual scan. Bad cavity flagged in hours, mould pulled for repair before the customer complains.
Virgin/regrind ratio drifts. Operator uses "a little more regrind" when virgin stock runs low. Customer fails their drop test 3 months later. Blame goes everywhere.
Approved virgin:regrind ratio enforced per batch with QA override + reason capture. Spec drift becomes a logged event, not a mystery.
PP / HDPE prices jumped 18% in 3 weeks. You're still honouring last month's ₹/kg quotes. Margin gone before you notice.
Live polymer-price feed (or daily manual update) auto-revalues open quotes. Customer sees the new price OR quote expires.
EPR returns under Plastic Waste Management Rules 2022 are mandatory. You've never filed. CPCB notice arrived.
EPR module tracks brand-owner registration, packaging category, weights, recycler certificates. Auto-generates CPCB-format quarterly returns. Notices stop.
Mould-change downtime is logged on paper. Setter says "30 minutes"; production lost 90 minutes. Nobody knows because nobody adds it up.
Mould-change start/end auto-captured on the machine HMI OR via supervisor mobile scan. Downtime reason coded. OEE dashboard shows the real number.
Real ROI, with numbers we can defend
Average year-one scrap drop from cavity-wise yield tracking + virgin/regrind enforcement.
Quote accuracy after live polymer-price revaluation kicks in — measured against actual material cost realised on the PO.
On-time EPR returns to CPCB across deployed units — zero notices since go-live.
Average Overall Equipment Effectiveness improvement from real mould-change downtime tracking + bad-cavity early detection.
Built for this industry, not adapted from generic ERP
Per-Mould Cycle-Time Costing
Actual cycle time × actual scrap × actual operator cost per mould. See which products are loss-leaders in your mix before they wreck the P&L.
Cavity-Wise Yield Tracking
12-cavity mould with one bad cavity wastes 8% of every shot. The system captures good/bad per cavity from PLC OR manual scan. Spot the bad cavity in hours, not weeks.
Virgin / Regrind Ratio Control
Batch-level virgin:regrind ratio recorded against the approved spec. QC linked to ratio. Customer complaint cascades from spec drift end here.
Live Polymer Price Quoting
PP / HDPE / PVC / PET prices swing 15-20% in weeks. Live price feed (or manual daily update) auto-revalues open quotes — no more honouring last month's ₹/kg on this month's order.
EPR / CPCB Compliance
Plastic Waste Management Rules 2022 made EPR returns mandatory. The system tracks brand-owner registrations, packaging category, weights, and auto-generates CPCB-format returns.
Machine HMI Integration
Read cycle count + good/reject from injection-moulding machine HMI via OPC UA, Modbus, or Euromap 63. Falls back to manual entry for older machines.
How Omeecron Plastic Manufacturing ERP runs your factory
80+ ready modules, grouped by what you do every day
Polymer & Material
- Raw polymer master (PP/HDPE/LDPE/PVC/PET/ABS/PC)
- Lot-wise GRN with COA capture
- Virgin / regrind / master-batch inventory
- FIFO polymer picking
- Polymer price-trend dashboard
- Auto-reorder triggers
Mould & Tooling
- Mould master with cavity count + cycle spec
- Mould health log (shots fired, PMs)
- Mould-to-product mapping
- Mould-change time tracking
- Mould rework / refurbishment log
- Mould-cost amortisation per part
Production & Cavity Yield
- Shift-wise production capture
- Cavity-wise good/reject per shot
- Cycle-time variance vs spec
- Operator + machine + mould combo tracking
- Down-time reason coding
- OEE dashboard (availability × performance × quality)
Quality & Spec
- Customer-approved virgin/regrind ratio
- In-process QC checkpoints
- Dimensional inspection log
- Customer complaint + CAPA
- PPAP / FAI documentation
- IATF 16949 / IS 14904 records
Sales & Quoting
- Live polymer-price-linked quoting
- Mould-cost amortisation in quote
- Tooling-charge invoicing (separate SAC)
- Customer-specific rate cards
- PO release schedules
- Sample-cum-PPAP tracking
GST & EPR Compliance
- GST + 1-click E-Way Bill (NIC API)
- Auto e-Invoice IRN (≥ ₹5 Cr)
- Plastic Waste EPR returns (CPCB)
- Brand-owner registration tracking
- Recycler certificate management
- Category-wise plastic weight register
On the roadmap · Rolling out through 2026
AI assists on the roadmap for your moulding floor.
AI assists are rolling out on the Omeecron platform through 2026 — included on the Growth plan when they ship, no extra cost. Here's exactly where AI will help in your factory's daily flow:
- 📄 Document AI (OCR + auto-fill): Polymer supplier COAs (MFI / density / lot) and customer PPAP docs → GRN entry + BOM compliance flags auto-populated, with the lot trail intact.
- 👁 Quiet Watchdog (anomaly detection): Per-mould cycle-time drift, per-cavity yield outliers, and supplier polymer-quality regression — caught the same shift, not at the monthly OEE review.
- 💬 Ask Your ERP (vertical chatbot): "Which mould had the worst yield this week?" · "Polymer price trend last 30 days" — answer in the chat bubble, no Excel pivot needed.
These are planned features, not live today. We're building them in the open and Growth-plan customers get them free as they ship. Want early-access? WhatsApp us.
Who is this for?
- Owner-operators of 15–200 person plastic moulding units
- Production heads tracking per-mould + per-cavity yield
- QC heads enforcing virgin/regrind ratio + customer-spec compliance
- Purchase heads navigating PP / HDPE / PVC price volatility
- Finance heads managing GST + EPR + ITC reversal
- Auto-ancillary suppliers handling PPAP / IATF 16949 customers
- FMCG-packaging moulders filing EPR returns under Plastic Waste Rules 2022
- Blow-moulders + extrusion units running the same workflow with different process specs
Pre-configured for Indian regulatory requirements
Omeecron vs Plex / IQMS (Dassault) / Tally + Excel
See how we stack up feature by feature.
| Feature | Omeecron | Plex / IQMS (Dassault) / Tally + Excel |
|---|---|---|
| Built for Indian plastic manufacturers |
Yes
|
Generic / global
|
| Per-mould cycle-time costing |
Built-in
|
Custom dev
|
| Cavity-wise yield tracking |
PLC + manual
|
Not available
|
| Virgin / regrind ratio enforcement |
Out of box
|
Manual / paper
|
| Live polymer-price quote revaluation |
Built-in
|
Manual re-quote
|
| EPR / CPCB plastic-waste returns |
CPCB-format export
|
Manual filing
|
| PPAP / IATF 16949 documentation |
Native
|
Add-on
|
| Machine HMI integration (Euromap 63 / OPC) |
Built-in
|
Custom dev
|
| GST + auto e-Invoice + E-Way Bill (NIC) |
Native
|
Manual portal
|
| Monthly cost (30-person unit) |
From ₹1,700
|
₹15,000 to ₹3L+
|
Built for Indian plastic manufacturers
Per-mould cycle-time costing
Cavity-wise yield tracking
Virgin / regrind ratio enforcement
Live polymer-price quote revaluation
EPR / CPCB plastic-waste returns
PPAP / IATF 16949 documentation
Machine HMI integration (Euromap 63 / OPC)
GST + auto e-Invoice + E-Way Bill (NIC)
Monthly cost (30-person unit)
Pick a Plan That Fits Your Factory
Start small, scale when ready. All plans include free implementation support to get you live.
Starter
- All core modules included
- GST + 1-click E-Way Bill (NIC API)
- Cloud access on web + mobile
- Email + WhatsApp support
- * Custom modules charged separately
Growth
- Everything in Starter
- Multi-GSTIN single login
- Priority WhatsApp + phone support
- Free quarterly upgrades
- On-site visits in Gujarat (free)
- Multi-user role permissions
- * Custom modules charged separately
Enterprise
- Everything in Growth Annual
- Multi-company / multi-unit setup
- Dedicated implementation manager
- On-site training across India
- Custom modules included in scope
- SLA-backed uptime + dedicated support
- Fixed quote agreed upfront — no T&M
Starter
- All core modules included
- GST + 1-click E-Way Bill (NIC API)
- Cloud access on web + mobile
- 20% off vs monthly (₹20,400 → ₹16,320/yr)
- Locked-in pricing for 12 months
- * Custom modules charged separately
Growth
- Everything in Starter Annual
- Multi-GSTIN single login
- Priority WhatsApp + phone support
- Free quarterly upgrades & on-site visits (Gujarat)
- 20% off vs monthly (₹42,000 → ₹33,600/yr)
- Free onboarding & data migration
- Locked-in pricing for 12 months
- * Custom modules charged separately
Enterprise
- Everything in Growth Annual
- Multi-company / multi-unit setup
- Dedicated implementation manager
- On-site training across India
- Custom modules included in scope
- SLA-backed uptime + dedicated support
- Fixed quote agreed upfront — no T&M
* Anything outside the standard module set — bespoke compliance reports, integration with specific machinery or instruments, workflows unique to your factory — is quoted separately on Starter and Growth plans (monthly or annual). Enterprise customers get custom modules included in their fixed scope. Annual plans are priced as monthly × 12 × 0.80 — a flat 20% prepay discount, locked for 12 months. We share a written quote before any custom work begins. No surprises, no time-and-materials billing.
Feature availability by plan
Pricing varies by billing period (see toggle above) — features are identical for monthly and annual on the same plan.
| Feature | Starter | Growth | Enterprise |
|---|---|---|---|
| Per-mould cycle-time costing | |||
| Cavity-wise yield (manual entry) | |||
| Virgin / regrind ratio enforcement | |||
| GST + auto e-Invoice + E-Way Bill | |||
| EPR / CPCB returns (Form-IV + Form-V) | |||
| Polymer price tracking (manual daily) | |||
| Multi-GSTIN single login | |||
| IATF 16949 / PPAP documentation pack | |||
| Live polymer-price feed integration | |||
| Priority WhatsApp + phone support | |||
| On-site visits in Gujarat (free) | |||
| Free quarterly upgrades | |||
| Machine HMI (Euromap 63 / OPC / Modbus) | |||
| Multi-unit / multi-company setup | |||
| Dedicated implementation manager | |||
| On-site training across India | |||
| SLA-backed uptime |
Frequently Asked Questions
Quick answers about Indian Injection Moulding, Blow Moulding & Extrusion Units.
Two modes: PLC-integrated for modern machines, supervisor-mobile-scan fallback for older ones. Both produce the same per-cavity report.
- Modern machines (Euromap 63 / OPC UA / Modbus): cavity-wise output read automatically from the controller
- Older machines: supervisor scans the mould QR at start of shift, enters cavity-wise good/reject counts at end of shift
- Sample-based: scan 1 in N shots through a vision system if cycle time is too fast for manual
- All three modes feed the same per-cavity yield report — bad cavity surfaces within hours regardless
- Custom PLC adapters quoted on Enterprise scope
Daily polymer prices entered manually OR pulled from a paid feed (PetroChemWire / Plastemart / your broker). Quote engine revalues open quotes against the latest price automatically.
- Manual mode: your purchase head enters daily PP / HDPE / LDPE / PVC / PET / ABS prices each morning
- Feed mode: integrate a paid commodity feed (PetroChemWire, Plastemart, broker WhatsApp parser)
- Quote engine flags open quotes that crossed your tolerance band (e.g. ±5%)
- Auto-revalue + email customer the new price OR mark the quote expired
- Historical price ledger tracks every revaluation event
Yes — the EPR module tracks the data CPCB asks for in the quarterly + annual returns and exports in their accepted format.
- Brand-owner / producer / importer registrations tracked
- Packaging category (rigid / flexible / multi-layered / compostable) per SKU
- Per-SKU packaging-material weight captured at packing
- Recycler certificates uploaded against returns
- Quarterly return (Form-IV) and annual return (Form-V) auto-prepared
- State Pollution Control Board notices addressed before they escalate
Tooling-charge invoicing uses a separate SAC and a separate invoice cycle. The system tracks tool amortisation independently of part-pricing.
- Tooling invoiced upfront OR amortised over agreed shot count
- Mould-cost amortisation embedded in part-price quoting (so margin is real)
- Customer-owned vs Omeecron-owned tooling tracked separately
- Mould PM schedule maintained even when customer owns the tool
- Amortisation completion triggers a "fully recovered" flag — part price can drop on renewal
Yes — PPAP packs and IATF 16949 records are first-class workflows. Auto-ancillary customers (Tier-1, Tier-2) get the documentation they need without ad-hoc scrambling.
- Sample submission with PSW (Part Submission Warrant) auto-populated
- Dimensional report templates for FAI
- Control plan + PFMEA + flow chart documents linked per part
- Customer-specific deviation requests + approvals tracked
- Annual customer audit prep-pack one-click generated
All three workflows are supported: injection moulding (primary use case), blow moulding (PET / HDPE bottles), and extrusion (pipes / sheets / profiles). The data model adapts.
- Injection: cavity-wise yield, cycle time, mould PM are the focus
- Blow moulding: parison weight, bottle wall thickness, preform spec captured
- Extrusion: line speed, gauge variation, take-off rate, downstream cut-length
- Common: virgin/regrind ratio, polymer price tracking, EPR returns, GST
- Choose your dominant process at setup; the workflow templates adjust
10–14 working days. PLC integration is the variable — manual-entry mode goes live in 7 days.
- Day 1–3: Master migration (polymer, mould, customer, part, BOM)
- Day 4–6: PLC integration validated (skip if going manual-entry first)
- Day 7: User training (online OR on-site if Gujarat / NCR / TN)
- Day 8–10: First parallel shift logged + validated
- Day 11–14: Cutover with reconciled ledgers
Yes — multi-GSTIN is included on Growth and Enterprise plans. Common pattern in plastic groups (manufacturer + trading + recycler arm).
- Each GSTIN keeps its own ledgers, banks, and invoice series
- Inter-company invoices (manufacturer → trading) auto-handled with correct ITC
- EPR returns can be filed entity-wise or consolidated
- Sister-unit material transfers tracked with E-Way Bill
Pricing starts at ₹1,700/month for the Starter plan, with a flat 20% discount when you pay annually.
- Starter — ₹1,700/month or ₹16,320/year: polymer + mould + production + GST + E-Way Bill + manual cavity-yield + EPR returns
- Growth — ₹3,500/month or ₹33,600/year: + multi-GSTIN, IATF / PPAP module, live polymer price feed, priority support, free Gujarat on-site
- Enterprise — Custom quote: + PLC integration (Euromap 63 / OPC UA / Modbus), multi-unit, dedicated manager, custom polymer-feed integration, SLA-backed uptime
Machine HMI integration is included on Enterprise; quoted separately on Starter / Growth based on machine count and protocol.
Yes — every plan includes ongoing support, free upgrades, and statutory advisory updates (GST + EPR + CPCB notifications).
- All plans: Email + WhatsApp support, Mon–Sat 9 AM – 7 PM IST
- Growth: + Priority phone support, free quarterly upgrades, free Gujarat on-site visits, free EPR / GST law-change advisories
- Enterprise: + Dedicated implementation manager, SLA-backed uptime, on-site across India, new PLC adapters included as released
Glossary — terms used on this page
- Cavity
- A single product-shaped cavity in a mould. A 12-cavity mould produces 12 parts per shot. Tracking yield per cavity (not just per shot) is the difference between catching a bad cavity in hours vs weeks.
- Virgin / Regrind
- Virgin = freshly produced polymer pellets. Regrind = reclaimed scrap ground back into pellets. Customer specs typically allow a maximum regrind ratio (e.g. ≤ 15%) before mechanical properties degrade.
- Cycle Time
- Total time for one moulding shot — fill, pack, cool, eject. Variance vs spec is the #1 hidden cost in injection moulding (every extra second × shots per shift × shifts per day = real money).
- EPR
- Extended Producer Responsibility — brand-owners + producers + importers of plastic packaging must register with CPCB and meet annual collection-recycling targets under Plastic Waste Management Rules 2022.
- MFI
- Melt Flow Index — measure of how easily molten polymer flows under standard conditions (g/10 min). Critical spec at GRN: out-of-spec MFI causes downstream cycle-time and quality issues.
- PPAP
- Production Part Approval Process — auto-ancillary documentation pack (PSW + dimensional + material certs + control plan) required before any production part can ship to a Tier-1 customer.
Get a personalised demo & quote
Reply within 24 hours. We’ll walk through your factory workflow, show the modules that matter for you, and quote any custom modules separately — no obligation.