Diagnose the Failed Rollout
Reviewed the first vendor's implementation against how scrap actually moves through the plant, and identified the rigid BOM as the root cause of the stock drift.
Case Study · Recycling & Green Manufacturing
A recycling plant's first ERP failed.
A recycling plant's first ERP failed.
Here is what replaced it
Rwenzori Process turns post-consumer plastic scrap into food-grade rPET, rHDPE and rPP at over 1,000 tonnes a month. Their first ERPNext rollout, built on a textbook bill of materials, could not survive contact with how recycling actually works.
The Outcome
What changed, in numbers
1,000+ t
Monthly Throughput Costed
Every batch across that volume now has a real, yield-based cost instead of a textbook estimate.
100%
Operations Stability
No more reverting to manual registers when the system's numbers stopped matching the floor.
Yield-Based
Precision Costing
Cost-per-kilo tracks the grades a batch actually produced, not a fixed input-to-output ratio.
Retired
Manual Registers
The paper ledgers the floor team fell back on during the failed rollout are no longer needed.
About the Client
A recycler running at a scale
A recycler running at a scale
a spreadsheet was never built for
Rwenzori Process Private Limited, based in the industrial zone of Sanand near Ahmedabad, manufactures high-purity, food-grade recycled PET flakes, recycled HDPE and recycled Polypropylene granules at an output exceeding 1,050 metric tonnes a month.
The process takes post-consumer plastic scrap through washing, shredding and colour-sorting before it becomes reusable, high-grade manufacturing raw material - a physical process that behaves nothing like the fixed-ratio manufacturing most ERP systems are built around.
Before Exalix Tech, Rwenzori had already engaged another ERPNext implementation vendor. That system went live and immediately produced severe mismatches between what the ERP recorded and what was actually happening on the floor.
Project at a glance
- Industry
- Plastic Recycling
- Location
- Sanand, Gujarat
- Monthly Capacity
- 1,050+ metric tonnes
- Products
- rPET, rHDPE, rPP
- Prior State
- Failed ERPNext rollout
- Website
- rwenzori.in
- Manufacturing (Yield BOM)
- Quality Inspection (Grading)
- Stock & Valuation
- Buying
- Accounting
- Daily AMC Support
The Challenge
A textbook implementation
A textbook implementation
meets a real recycling floor
None of these four problems were the software's fault in isolation. Together, they explain why the first rollout ended with operators back on paper ledgers.
A BOM that assumes recycling doesn't happen
Standard bills of material assume a kilo in gives a kilo out. Input purity for sorted scrap changes with every load, so stock entries drifted from day one and never caught up.
One input, several outputs, no way to log it
A single batch of sorted scrap yields multiple grades at once - clear flakes, coloured flakes, waste caps, dirt. The standard system had no way to record more than one output grade per input.
A floor team that stopped trusting the numbers
When the system's figures kept disagreeing with what was physically on the floor, workers quietly went back to manual registers rather than keep fighting the software.
Support that took days to answer
When billing validation or a tax calculation broke, the previous vendor's response time stalled invoicing and freight dispatch for days at a time.
The Solution
Rebuilt around actual yields, not a textbook ratio
Fixing this meant changing how the manufacturing flow itself was modelled - and rebuilding trust with a floor team that had already been let down once.
Yield-Based BOM Rebuild
Replaced the fixed-ratio bill of materials with scrap-yield templates, so a Work Order records the actual multi-grade output a batch produced instead of an assumed one-to-one ratio.
Inflow Quality Grading
A grading tool for incoming baled scrap assigns a grade on arrival and links it to raw material valuation, so cost reflects the material that actually came in.
Floor Team Retraining
Retrained operators on the shop floor until they trusted what they were entering, rather than handing over a system and leaving - which is what caused the first rollout to fail.
Daily AMC Support Desk
A structured, SLA-backed support desk answers accounting queries, logistics errors and ledger corrections the same day, so operations are never blocked waiting on a fix.
The Rescue
From a broken rollout
From a broken rollout
to a system the floor trusts
Rebuild the Manufacturing Flow
Replaced the fixed BOM with yield-based Work Order templates and an inflow grading tool tied to raw material valuation.
Retrain the Floor Team
Sat with operators until they trusted the new entries, rebuilding the confidence the failed first rollout had cost.
Stand Up Daily Support
Established an SLA-backed AMC desk so a billing or tax issue gets same-day resolution instead of a multi-day wait.
Client verdict
1,000+ t
Costed Every Month
"Exalix Tech rebuilt the process flow around our actual yields instead of a textbook BOM, sat with the floor team until they trusted what they were entering, and stayed reachable day to day. At over a thousand tonnes a month we can finally cost a batch properly, and the manual registers are gone."Ritesh Pandit CFO, Rwenzori Process
Questions
Recycling ERP FAQs
Because it assumes a fixed input-to-output ratio - a kilo of raw material always yields a kilo of product. Recycling does not work that way: input purity varies with every load, and one batch of sorted scrap produces several grades of output at once, which a static BOM simply cannot record.
Instead of a fixed consumption ratio, the Work Order records the actual multiple output grades - clear flakes, coloured flakes, waste, dirt - against the raw scrap weight that went in. ERPNext then calculates the real scrap-loss percentage and adjusts the valuation rate of each output grade accordingly.
Yes, and it is a more common request than people expect. Rwenzori's first rollout with another vendor could not survive contact with a real recycling plant. Rescuing it meant rebuilding the manufacturing flow around actual yields rather than starting over, and retraining the floor team who had lost trust in the numbers.
Through an inflow grading step. Baled scrap is assigned a grade on arrival, and that grade is linked to the raw material valuation, so the cost of a batch reflects the actual quality of what came in rather than an assumed standard input.
Day-to-day operational assistance: reconciling physical inventory mismatches, resolving e-invoice validation errors with the GST portal, configuring new tax structures, and fixing ledger corrections - the class of issue that stalls billing and dispatch if it waits more than a day.
Yes. Rwenzori runs rPET, rHDPE and rPP through the same yield-based manufacturing flow. The BOM and grading logic key off the actual material and grade, not the polymer type, so it extends across product lines without separate configuration.
It depends more on retraining the floor team than on reconfiguring the software. The BOM and grading rebuild can move quickly; rebuilding trust with operators who have already been burned once takes longer, and rushing that step is usually why the first attempt failed.
Start a Conversation
Stuck with an ERP
Stuck with an ERP
that never fit the floor?
That is exactly where Rwenzori started. A rollout built on assumptions the process does not actually follow is not a dead end - it is a rebuild, and one the floor can be brought back to trusting.
No generic brochures. Your first call is with a lead consultant who will talk through your actual process and where the current system stopped matching it.
Call +91 77780 25099 · Email info@exalixtech.com
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