Four Plants. One Plan.
How Avon Plastic Industries unified 4 manufacturing units, 11 Odoo apps, and 5 product lines into one connected ERP backbone with real-time costing and finite capacity planning.
Avon Plastic Industries Private Limited
19 mm conduit to 50 mm heavy-duty pipe in light, medium, heavy and extra-thick grades — each a separate recipe, die and yield.
“Cost should be known before a decision is made, not reconstructed after it.”
The foundational design principle behind the Avonplast programme engineered by Prixgen
From Resin to Revenue, On One Platform
Explore how material, machine capacity, shop-floor execution, and profitability are locked into a single relational chain across all four manufacturing plants:
1. Multi-Plant Core
Four independent manufacturing units unified into a single group-level database.
Plants were previously planning on separate spreadsheets with zero centralized visibility.
Consolidated Odoo multi-company architecture with plant-specific ledgers and unified executive dashboards.
What Was Holding the Business Back?
PVC manufacturing has specific dynamics: fast raw material price shifts, heavy regrind recycling, finite machine tooling, and complex unit conversions.
Live Cost-Linked Pricing
Quotations dynamically link to real-time PVC resin input costs with automated approval gates and live customer credit exposure visibility.
Plant-Wise MRP I & MRP II
Material and machine capacity planned together, separately for every plant and product category, with finite line loading.
Digital Recipe & Die Control
Digital formulation management, die lifecycle logs, changeover sequencing, and shift-wise OEE tracking.
Process-Level Waste Lineage
Input-output variance control, capped regrind ratios to ensure pipe strength, and systematic scrap accounting.
Universal Single-Point UoM
Multi-plant stock ledgers where unit conversions between kg, metres, and pieces are resolved once inside the ERP core.
Real-Time Costing Engine
Live SKU-wise contribution margins, automated GST workflows, and multi-branch ledger consolidation.
Zero-Downtime Phased Rollout
No capability rolled out group-wide until proven on a single production line. Zero manufacturing shifts were lost.
On the Shop Floor with Avonplast
A high-precision look at manufacturing operations, heavy moulding machinery, and product catalog across the 4 units:
Avonplast Manufacturing Unit
Solar-roofed industrial plant powering high-capacity extrusion lines.
Moulding Shop Floor
Automated injection and blow moulding machinery with live OEE tracking.
Conduits, Fittings & Wiring
20mm & 25mm conduits, junction boxes, and bends across light, medium, and heavy grades.
The Avonplast & Prixgen Teams at Go-Live, April 2026
Successful 4-plant rollout executed without losing a single production shift.
5 Unified Product Lines
Agriculture, plumbing, industrial, electrical, and water storage systems.
Relevant Part of the Software
A comprehensive view of the 11 Odoo applications currently active in production, alongside the scheduled Phase 2 expansions:
Manufacturing (MRP I & II)
Finite machine scheduling, multi-level BOMs, extrusion line speed, and moulding changeover control.
Inventory & Multi-Warehouse
Real-time stock ledgers across 4 plants with automated UoM conversions (kg, metres, pieces).
Sales & CRM
Dynamic pricing linked to live resin costs, automated quotation approval, and credit ceiling enforcement.
Quality Control
In-process wall thickness checks, pressure testing, and ISI compliance logging.
Maintenance
Machine runtime hours tracked directly from line output to trigger preventive maintenance.
To Summarize: The 6 Operational Shifts
Material and capacity are planned together, plant by plant, and each plan is committed within the same cycle.
Every kilogram charged is reconciled against every kilogram produced, by shift, line and SKU.
Costing runs continuously, with margin visible by SKU, line and plant instead of at month-end.
One unit-of-measure logic across kilograms, metres and pieces removed a recurring source of stock error.
Quotations move with input cost, protecting the margin floor against resin commodity swings.
Four units report on one structure that is comparable, consolidated and auditable.
Why PVC & Process Manufacturers Choose Prixgen
Since 2018, Prixgen Tech Solutions has helped manufacturers replace disconnected spreadsheets and legacy systems with an integrated ERP that finance, operations, and leadership can rely on:
Manufacturing Depth
More than 100 end-to-end ERP implementations across 18+ industries, including 10+ PVC, polymer, and plastics manufacturers.
Sector-Specific Design
Solutions designed around extrusion, moulding, and high-variant master data, with recipe-driven production that holds quality across shifts.
Finance-Led Implementation
Our team includes two qualified Chartered Accountants. We perform internal audit support and sit with your statutory auditor through balance-sheet close.
100% In-House Delivery
55 in-house Odoo functional and technical consultants, including 10 Odoo-certified specialists. Zero subcontracting or outsourcing.
Proven Low-Risk Method
Assessment, gap analysis, blueprint, phased implementation, and benefits tracking. Capability is proven at one line before group rollout.
Industry 4.0 on Odoo
Machine integration that captures runtime directly from the shop floor and drives preventive maintenance from actual equipment usage.
Run a PVC, Polymer or Process Manufacturing Plant?
Let's audit your shop floor and costing workflows. Our senior consultants will evaluate your current recipe management, machine scheduling, and margin visibility to build a tailored Odoo roadmap.
Schedule a Manufacturing Architecture Audit
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