Deckle Plus Paper Mill Trim Optimization
Mathematically optimal cutting patterns that bring trim waste from the 4 to 7% industry norm to under 0.5%
Developed by Apice Tech Private Limited, an RSBPL group company
Overview
Deckle Plus is trim optimization and end-to-end production management software for paper mills and converters. Its optimization engine (column generation followed by a knapsack solver) computes the best combination of reel widths to cut from each master reel, treating deckle width and blade count as hard limits. Around it sit customer orders, deckle runs, inventory with FIFO allocation, waste logging, delivery challans, and dispatch. Deckle Plus is built by Apice Tech Private Limited, an RSBPL group company, and is offered to RSBPL's manufacturing clients.
Key Features
Multi-Phase Optimization Engine
Column generation followed by a knapsack solver, respecting blade count and trim constraints as hard limits.
Sandbox What-If Analysis
Test alternate scenarios on isolated copies of any production run, with side-by-side waste comparison.
End-to-End Production Lifecycle
Customer orders, deckle runs, cutting patterns, waste event logging, delivery challans, and dispatch in one system.
Inventory & Material Intelligence
FIFO allocation with real-time stock by paper type, GSM, and width. Every reel is tracked through every draw.
Multi-Type Order Management
REEL, SHEET, and THERMAL order types with variance tolerances per customer.
Role-Based Access Control
Admins, Planners, Operators, and Supervisors, with every action recorded in an immutable audit trail.
Problems It Resolves
- Excessive trim waste from manual whiteboard deckle planning
- Production delays from schedules that take hours to prepare
- Infeasible cutting patterns discovered only at the machine
- No real-time visibility of reel inventory by grade, GSM, and width
Deckle Plus waste report showing trim waste by machine
Business Benefits
- Under 0.5% average trim waste, down from the 4 to 7% typical of manual planning
- 12 to 15% margin recovery from reduced waste
- Cutting plans in milliseconds instead of hours
- No dependency on a single senior planner
- Live in 48 hours, with no IT infrastructure changes
Who Is It For?
Pricing & Plans
Subscription priced by daily output, from $99/month (₹5,999/month in India) for mills up to 5 MT/day. Annual billing gives 2 months free. Full pricing at deckleplus.com/pricing.