The Client: Rwenzori Process
Based in the industrial zone of Sanand near Ahmedabad, Rwenzori Process Private Limited is a pioneering plastic recycling enterprise. The company manufactures high-purity, food-grade recycled PET (rPET) flakes, recycled HDPE (rHDPE), and recycled Polypropylene (rPP) granules, running at a massive output capacity exceeding 1,050 metric tonnes per month.
Their process takes post-consumer plastic scrap, washes, shreds, color-sorts, and processes it into reusable high-grade manufacturing raw material. To learn more about their sustainability goals, visit their website: https://www.rwenzori.in/.
The Challenge: A Broken Standard ERP
Before partnering with Exalix Tech, Rwenzori Process had engaged another ERPNext implementation vendor. However, the system went live with severe mismatches:
Rigid Bill of Materials (BOM)
Standard ERPNext assumes static BOM ratios (e.g. 1kg input always equals 1kg output). In plastic recycling, input purity varies daily, leading to massive stock entry discrepancies.
Co-product & Scrap Tracking Gaps
Sorting scrap yields multiple grades (rPET Clear, rPET Colored, Waste caps, and mud). The standard system couldn't log multiple finished output grades from a single scrap input batch.
Lack of Training & Trust
Workers on the factory floor weren't properly trained, leading to incorrect scrap receipts. Data errors compounded, forcing staff to revert to manual ledgers.
Inadequate Post-Implementation Support
When day-to-day validation or tax calculations failed, support response times were slow, stalling billing and freight dispatches.