Introduction
In the packaging material industry, speed and precision go hand in hand. Every roll of film, every batch of paper, every printed label has to be weighed, recorded, and dispatched accurately often across multiple shifts and dispatch points.
However, for many packaging factories, weighing and labeling remain manual tasks. Operators weigh materials on basic scales, write weights on paper, and enter them later into an Excel sheet or ERP. This delay often leads to errors, mismatched entries, and poor inventory visibility.
This case study explores how one packaging material manufacturer transformed its production and dispatch process using an industrial weighing scale with printer integrated with a custom-built Weighing ERP system eliminating manual errors, boosting productivity, and achieving real-time traceability.
The Client: A Leading Packaging Material Manufacturer
The client is one of India’s largest producers of flexible packaging films and laminated rolls used by FMCG, food, and pharmaceutical brands. With a daily production output of over 25 tons and multiple dispatch lines, they faced increasing challenges in maintaining weight accuracy, batch tracking, and dispatch documentation.
Their plant operated three main stages:
- Extrusion & Lamination Line – where rolls of film were produced.
- Printing & Slitting Line – where film rolls were customized for clients.
- Dispatch Section – where finished rolls were weighed, labeled, and loaded for transport.
Each roll needed a printed label showing weight, batch number, roll number, date, operator name, and QR code for traceability.
The Challenge
Before automation, the company faced several recurring problems:
- Manual Recording Errors – Operators recorded weights in registers, which were later entered manually into ERP. Mistakes and mismatched entries were common.
- Labeling Delays – Labels were printed separately using office printers, taking 30-40 minutes per batch.
- Traceability Gaps – During audits, linking a roll’s physical label to its ERP record was difficult.
- Inventory Inaccuracy – Dispatch teams couldn’t get live stock data, leading to duplicate entries or missing rolls.
- Compliance Risk – Without Legal Metrology compliant labels, the process lacked standardization and audit readiness.
They needed a solution that could directly link weighing, labelling, and ERP entry in one automated flow.
The Solution: Industrial Weighing Scale with Printer + Weighing ERP Integration
The team at Punit Instrument Private Limited implemented a customized weighing automation system built around two key components:
- Industrial Label Printing Weighing Scale – A robust platform scale with a built-in thermal printer.
- Capacity: 500 kg per roll
- Accuracy: ±0.05%
- IP Rating: IP65 (dust and moisture protected)
- Features: QR printing, tare function, and ERP connectivity
- Weighing ERP Integration Module – A middleware designed to connect the weighing system with the company’s ERP software in real time.
- Automated data capture from the scale
- Auto label generation with QR/barcode
- Live stock update in ERP
- Operator authentication and audit trail
How the System Works
The workflow was redesigned to ensure zero manual touchpoints:
- Operator Login: The operator logs in to the scale with an ID and selects the batch number.
- Product Placement: The roll is placed on the platform; the scale records the weight.
- Automatic Label Generation: Within 3 seconds, the system prints a label showing:
- Product name
- Batch number
- Net weight
- Operator ID
- Date and time
- QR code (linked to ERP record)
- ERP Sync: The same data is pushed automatically to the ERP database.
- Dispatch Tracking: When scanned at dispatch, the QR confirms weight, roll ID, and status no manual entry needed.
Measurable Results
After implementation, the improvements were immediate and measurable.
| Parameter | Before Automation | After Automation |
|---|---|---|
| Label printing time per batch | 30–40 mins | < 5 mins |
| Data entry errors | 8–10 per day | Zero |
| Dispatch accuracy | 91% | 99.9% |
| Operator productivity | 70 rolls/shift | 110 rolls/shift |
| ERP sync delay | 1–2 hours | Instant |
| Audit traceability | Manual | QR-code based |
| Calibration cycle | Manual logs | Automated reminders via ERP |
The return on investment was achieved within six months, thanks to improved speed, reduced labour dependency, and near-zero labelling errors.
Integration with ERP & Inventory Management
The biggest advantage came from ERP integration.
Previously, the store and dispatch teams worked in silos weights were updated manually after physical checks.
With the new Weighing ERP integration:
- Each label generated an automatic ERP entry.
- QR codes made every roll traceable from production to dispatch.
- Real-time stock visibility enabled faster invoicing and dispatch scheduling.
- The ERP generated calibration and batch reports automatically for audits.
This integration bridged production and administration, ensuring full alignment between factory floor data and business records.
Additional Benefits
- BIS & Legal Metrology Compliance – The label format now meets trade and audit standards.
- Zero Downtime Printing – Industrial-grade thermal transfer printers handle continuous operation.
- Digital Calibration History – Each scale’s calibration data is stored digitally.
- User Accountability – Each label includes operator ID, ensuring responsibility and transparency.
- Faster Dispatch Audits – QR-based scanning during loading verifies product authenticity.
Employee Perspective
Initially, there was hesitation among operators used to manual logs. But after training, they appreciated how easy the new system was.
“Earlier we spent hours writing weights and waiting for labels. Now it’s automatic. We just weigh, stick, and move to the next roll. It’s made our shifts smoother.” – Senior Operator, Dispatch Line 2
Even the quality control team benefited. They could scan any label and see full production and calibration data instantly from the ERP dashboard.
The ROI Breakdown
The client’s cost-benefit analysis showed:
- 40% reduction in manpower required for weighing and labeling
- 95% reduction in labeling errors
- 100% audit-ready traceability
- 25% faster dispatch turnover
- Payback period: 6.5 months
Beyond numbers, the biggest gain was peace of mind every product that left the factory was accurately weighed, labelled, and digitally traceable.
The Future: Expanding Across Units
After the successful pilot, the company decided to replicate the system across all their packaging units.
They are now connecting additional stations like raw material intake, quality inspection, and finished goods warehouse to the same Weighing ERP, creating a fully connected plant ecosystem.
The next upgrade will include:
- Cloud-based reporting
- IoT dashboards for real-time analytics
- Integration with supplier and client systems for live dispatch tracking
Conclusion
This case study proves that even in established industries like packaging materials, automation using a weighing scale with printer and ERP integration can deliver transformative results.
By connecting weighing, labelling, and data in one seamless system, the factory achieved what every manufacturer wants speed, accuracy, and complete traceability. The success of this project shows that investing in smart weighing systems is not just about hardware it’s about building a digital foundation for operational excellence.
For factories looking to industrial weighing automation solutions, labelling, and ERP synchronization.