Formula Digitisation
Migrated every chemical recipe into ERPNext Bills of Material, locking production to the one approved “golden recipe” per product.
Case Study · Construction Chemicals
Only the approved recipe
Only the approved recipe
reaches production
Rex Bond makes tile adhesives, grouts and epoxy systems for 100+ distributors and contractors. Formulas used to live in Excel, and a bad batch could not be traced back to what caused it. Every recipe is now version-controlled, and every bag is traceable.
The Outcome
What changed, in numbers
99%
Batch Traceability
Any bag on any shelf can be traced back to the raw material batch it came from.
Automated
Pricing Engine
Distributor schemes and taxes apply themselves - nobody argues over what was agreed.
Real-Time
Stock Visibility
Every warehouse visible at once, instead of a phone call to check what is on hand.
40%
Less Admin Work
Invoicing and inventory updates that used to be manual now happen without a keystroke.
About the Client
A chemicals maker where
A chemicals maker where
consistency is the product
Rex Bond is a fast-growing name in construction chemicals, producing high-performance tile adhesives, grouts and epoxy systems out of Ahmedabad - 500+ bags a day from more than twenty different raw chemical inputs.
The business serves a network of 100+ distributors and large contractors, each managed under its own pricing scheme, on top of a supply chain of volatile raw materials that have to be tracked precisely from arrival to finished bag.
In a chemicals business, consistency is not a nice-to-have - it is the product. A recipe trapped in a spreadsheet and a pricing scheme argued over by phone were both liabilities that grew with every new distributor.
Project at a glance
- Industry
- Construction Chemicals
- Location
- Ahmedabad, India
- Daily Output
- 500+ bags
- Raw Inputs
- 20+ chemical types
- Distribution
- 100+ distributors & contractors
- System
- ERPNext v15
- Manufacturing
- Stock (Batch)
- Buying
- Selling
- Quality Inspection
- Accounting
The Challenge
When the recipe and the invoice
When the recipe and the invoice
both live in someone's memory
None of these four problems showed up as a single failure. They compounded quietly, until a bad batch or a disputed invoice forced the question of what had actually been agreed.
Recipe variance
Formulas lived in spreadsheets, and every so often a batch ran off an outdated version of a recipe. Nobody could say with certainty which version was actually in use on the floor.
Traceability gaps
If a contractor reported a bad lot, tracing it back to the raw material batch behind it was close to impossible. There was no chain linking a finished bag to what went into it.
Distribution chaos
Sales teams promised delivery dates without knowing whether the additives needed to make the order were actually in stock, so promises and production frequently disagreed.
Pricing errors
With over a hundred distributors on different schemes, manual invoicing produced discount errors - and discount errors turned into payment disputes nobody could settle because nobody could prove what had been agreed.
The Solution
Version control for chemistry, not just for code
The goal was simple to state and precise to build: one approved recipe per product, one traceable batch per bag, and pricing that applies itself.
Formula Digitisation
Every chemical recipe moved into ERPNext Bills of Material, so only the approved “golden recipe” can be pulled for production - never an outdated one.
Batch Inventory
Batch tracking on raw materials and finished goods alike, with expiry management, giving a full chain from vendor to factory to customer.
Quality Quarantine
Incoming raw material - cement grade, polymers, additives - is quarantined on arrival and only released to production once it clears a lab test recorded in the ERP.
Automated Distribution
Pricing rules configured per distributor tier, so invoices calculate the right price, discount and tax automatically instead of by hand.
The Implementation
Four phases, from the formula
Four phases, from the formula
to the invoice
Batch Inventory
Enabled batch tracking with expiry management on raw materials and finished goods, creating a traceability chain from vendor to factory to customer.
Quality Control
Integrated quality inspection templates so incoming material is quarantined until it passes a lab test recorded in the system.
Automated Distribution
Configured pricing rules per distributor tier, so invoices auto-calculate price and tax based on the customer group instead of a manual lookup.
Client verdict
99%
Batch Traceability
"In construction chemicals, consistency is the product. The biggest benefit for us now is clarity. Earlier we had to call people to check stock or orders; today it is visible instantly across every warehouse, only the approved recipe can reach production, and pricing applies itself instead of being argued over."Mahendra Patel Managing Director, Rex Bond
Questions
Process manufacturing FAQs
Through bill of material version control. Each formula has one approved, active BOM, and a Work Order can only be raised against it. Superseding a recipe retires the old version rather than leaving two live copies for someone to pick the wrong one from.
Yes, once batch tracking is enabled on both raw materials and finished goods. Every stock movement carries its batch number through manufacture, so a bag on a shelf links back to the exact input batch it was made from - a lookup rather than an investigation.
It tracks the manufacture date and expiry date on every batch and supports First-Expiry-First-Out picking, so older material is used or dispatched before it can spoil.
Yes. A Quality Inspection can be attached to the purchase receipt, and the batch stays in a quarantine warehouse until the inspection is recorded as passed - so a failed batch never reaches production by accident.
Yes, through Pricing Rules keyed to customer group, territory or item. Each distributor's scheme applies automatically at invoicing, which is what removes the manual discount errors that used to cause payment disputes.
Yes. Item Variants let one base item cover multiple weights or types - 20kg and 40kg bags, for instance - while sharing the same underlying formula and raw materials.
Yes, and it is simpler to set up with fewer product lines. The same BOM governance, batch tracking and quarantine workflow scales down cleanly - there is just less configuration before go-live.
Start a Conversation
Still arguing over
Still arguing over
whose price list is right?
That is exactly where Rex Bond started. The gap between what a recipe says on paper and what actually reaches the mixer is where inconsistency, disputes and untraceable defects all come from.
No generic brochures. Your first call is with a lead consultant who will talk through your actual formulas and distribution setup.
Call +91 77780 25099 · Email info@exalixtech.com
Request received
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