End-to-end production management for paper mills. Minimize trim waste with mathematically-optimal cutting patterns and manage your entire production lifecycle in one platform.
| ORDER WIDTH | ORDER QTY | ALLOCATED | STATUS |
|---|---|---|---|
| 850 mm (REEL) | 42 MT | 42 MT | ✓ Filled |
| 720 mm (REEL) | 78 MT | 78 MT | ✓ Filled |
| 480 mm (REEL) | 42 MT | 42 MT | ✓ Filled |
| 350 mm (REEL) | 60 MT | 60 MT | ✓ Filled |
Every shift planned on notepads and spreadsheets leaves significant trim on the floor. Over 12 months, this waste is a massive, preventable financial drain.
Planners default to a few simple cut layouts, resulting in average trim of 4%–7% that goes straight into waste balers as scrap.
Calculating blade positions manually takes 2–3 hours per schedule, delaying slitter lines and pushing back order lead times.
The entire cutting setup lives in the memory of one or two senior planners. If they're absent, scheduling halts and machines sit idle.
Without live stock tracking, there's no correlation between pending orders and available reels, which forces duplicate material procurement.
Manual calculations regularly produce plans that exceed the machine's blade count or don't meet waste targets, requiring restarts.
Without a tracking system, management cannot see trim recovery trends, waste event reasons, or per-run profitability in daily operations.
We replace guesswork with instant, mathematically-proven permutations. See how your operations look on day one of deploying the matching engine:
Proprietary algorithm with mathematically proven patterns
Deckle Plus combines advanced operations-research optimization with full production lifecycle management, purpose-built for paper manufacturing.
Our proprietary optimization algorithm finds cutting patterns that minimize trim waste across all order widths, respecting your machine's blade count and minimum trim constraints.
Create isolated copies of any production run, freely modify allocations and patterns, test alternate cutting scenarios, all without affecting live production. Promote validated results when you're ready.
Manage everything in one workflow: customer orders, deckle runs, cutting patterns, waste event logging, delivery challans, and dispatch, with full status tracking at every stage.
Track raw reel intake from suppliers, monitor consumption per production run via FIFO allocation, and view real-time stock levels by paper type, GSM, and width at any point in time.
Support REEL, SHEET, and THERMAL order widths with variance tolerances, customer labels, GSM requirements, and full status tracking from draft to completion.
Separate access for Admins, Planners, Operators, and Supervisors. Every action is logged in a full audit trail with user, timestamp, and before/after state.
Live KPIs, active run status, waste trend charts, and production performance reports. Dedicated reports for orders, waste events, and material consumption.
Queue and prioritize deckle runs across machines, manage machine downtime windows, and track completion progress against the production schedule.
Explore the full sandbox experience on its dedicated page with machine setup, manual pattern building, optimization runs, and PDF export.
The live optimizer is now hosted on a dedicated page for a cleaner landing experience.
Go to SandboxEnter your production capacity and paper grade pricing to see what trim waste reduction means for your bottom line.
Enter your current chemical pulp output or corrugation metrics to inspect how much waste reduction pays back.
Equals saving approx 171 Tons of scrap fibers.
Based on benchmarks using our proprietary optimization algorithm against standard paper mill cutting scenarios.
Typical manual spreadsheet estimations
Column generation optimization
Pattern generation that previously took 2–3 hours now completes in under a second.
Based on average mill output of 300–800 MT/mo and paper price $500–800/ton. Use the ROI calculator above for your specific numbers.
Deckle Plus is onboarding its first batch of paper mills globally. Early access partners work directly with our team to configure their machine profiles, paper types, and production workflows and get priority support during rollout.
No commitment required. We'll contact you within 24 hours to schedule a walkthrough.
The core production platform is live. These integrations and capabilities are actively in development or planned for the next release cycle.
Early access partners can request prioritization of any item on this roadmap.
Answers to the most common questions about deckle optimization, production workflow, and platform capabilities.
Deckle cutting optimization software calculates the mathematically best combination of paper widths that can be cut simultaneously from a machine's deckle (maximum usable width) to minimize trim waste. Deckle Plus uses a two-phase algorithm (column generation followed by a knapsack solver) producing cutting patterns with less than 0.5% average trim waste, compared to the 2-5% typical of manual whiteboard planning in paper mills worldwide.
At typical Kraft paper prices ($600-900 per tonne), a 50 t/day mill losing 3% to trim waste discards roughly 1.5 tonnes per day, worth $27,000-$40,000 per month in avoidable raw material costs. Reducing waste from 3% to under 0.5% with Deckle Plus typically recovers $20,000-$35,000 per month, making the software ROI-positive within the first week of use.
Deckle width is the maximum usable paper width on a winder, rewinder, or slitter machine, typically 1,800 mm to 5,600 mm depending on machine size. All cutting patterns must fit within the deckle width. Deckle Plus uses each machine's configured deckle width and blade count as hard constraints, so no infeasible pattern is ever suggested.
Deckle Plus supports three order types: REEL (standard roll widths), SHEET (width × length dual-dimension orders), and THERMAL (thermal paper rolls with core diameter and OD specification). All three types coexist in the same production run. Paper grades supported include Kraft, Duplex Board, Cylinder Mould, Coated, Newsprint, Tissue, and custom grades, each with independent GSM values.
Most mills go live within 48 hours. Day 1: our team configures machines, paper types, and GSM profiles during an onboarding call. Day 2: the planner enters real orders, runs the first optimization, and begins production tracking. Deckle Plus is a cloud-based SaaS platform requiring no IT infrastructure changes. It works in any modern web browser.
The Sandbox creates an isolated copy of any production run where planners can freely modify order widths, quantities, and patterns without affecting the live run. After changes are made and re-optimised, the Sandbox shows a side-by-side waste comparison. If the modified plan is better, it can be promoted to replace the live run (Suite plan). This is the safest way to handle last-minute order changes mid-shift.
Yes. The inventory module records raw material intake from suppliers, tracks each reel's remaining weight through every production draw, and automatically applies FIFO (First-In, First-Out) allocation across runs. Stock is visible in real time by paper type, GSM, and width, with low-stock alerts configurable per grade.
REST API integration (Suite plan) enables custom data pipelines between Deckle Plus and any ERP including SAP S/4HANA, Oracle, TallyPrime, or custom systems. Native SAP and TallyPrime connectors are on the roadmap. Excel and CSV bulk order import is in development for Q3 2026.
Deckle Plus serves Kraft paper mills, Duplex board plants, Cylinder mould board mills, coated and newsprint producers, BOPP and masking tape manufacturers, self-adhesive label printers, flexible packaging converters, corrugated board producers, and tissue converters. It scales from small converters at 5 t/day to large integrated mill groups at 500+ t/day.
Deckle Plus has four built-in roles: Admin (full access including machine and user configuration), Planner (order entry and optimization), Operator (floor execution and waste logging), and Supervisor (read-only analytics and production oversight). All actions are recorded in a full, immutable audit trail. There is no limit on the number of users per role.
Whether you're running a high-capacity Kraft paper mill or a mid-size duplex board plant, Deckle Plus handles your complete production workflow, from customer order entry through to dispatch challans.
We'll configure your machine profiles and paper types before the walkthrough.