Ever wondered what goes into manufacturing the humble paint tin sitting on a hardware store shelf? Behind every paint container from Asian Paints or Kansai Nerolac Paints lies a highly coordinated production process involving sheet metal slitting, epoxy coating, offset printing, precision punching, and rigorous multi-stage quality inspections, all operating across parallel production lines.

To showcase how manufacturers can streamline and gain complete visibility across this extensive production journey, we created a complete ERP implementation service for a tin container manufacturing plant. This detailed 41-minute session demonstrates how every stage - from raw material intake to final dispatch - can be digitally connected, monitored, and managed through a single integrated ERP system.

Watch the full walkthrough here: https://www.youtube.com/watch?v=5C96SYH34r0

The video follows a complete business cycle centered around a 15,000-container order from a leading paint manufacturer, showcasing every transaction, production stage, quality checkpoint, and operator activity seamlessly tracked within the ERP system.

What the Demo Covers 

The Engineering - Sheet Cutting Mathematics 

Let us start with the maths behind minimizing material wastage. How does an 880mm × 1040mm tinplate sheet transform into a 4-litre paint container? 

The answer involves some elegant geometry. One sheet is slit into exactly 4 strips of 220mm width - zero edge waste because the dimensions were chosen specifically for this container size. Each strip is then coated, printed, and punched into rectangular body blanks. Two blanks per strip, with just a 4mm gap and 0.4% scrap. 

The container’s bottom follows a different path. Circular blanks of 165mm diameter are punched from rectangular strips, and here the scrap jumps to 37%. That's the unavoidable physics of cutting circles from rectangles; no amount of optimization can change this significantly with single-row nesting. 

To make the analysis even more practical, the video also includes a detailed 8-page engineering document covering yield calculations, scrap analysis, and per-unit material costing down to the last penny.

The Sales Cycle 

A Sales Order from a leading paint manufacturer - 15,000 containers at Rs 65 each and 15,000 lids at Rs 15 each. Total order value: Rs 12 lakhs. The system tracks this order through production, delivery, and invoicing. 

 The Purchase Cycle - With a Quality Twist 

A Purchase Order to Tata Tinplate for 2,000 body sheets and 1,500 lid sheets. When the material arrives, the quality team samples and inspects against 6 parameters - thickness, tin coating weight, hardness, surface roughness, edge waviness, and temper grade. 

The body sheets pass. All 2,000 accepted. But the lid sheets don’t pass muster fully! Edge waviness measured at 0.45mm against a maximum specification of 0.30mm. 200 sheets rejected. The system automatically splits the stock - 1,300 accepted sheets to the production warehouse, 200 rejected sheets to a separate Rejected Store. No manual adjustment, no paperwork, the quality gate is built into the receiving process. 

Manufacturing - 3 Lines, 9 Operations, 6 Operators 

Three Work Orders run in parallel: 

• Body Line: the longest chain with 5 operations: slitting, internal epoxy coating, external white primer, offset printing, and punching. Each operation has its own Job Card with the operator's name, start time, end time, produced quantity, and scrap count. Ravi Jadhav runs the shear. Santosh Gaikwad handles both coating passes. Manoj Pawar operates the printing press. Amit Shinde runs the body punch.
• Bottom Line: 2 operations: slitting and circular punching. Ravi Jadhav again on the shear, Pravin Kale on the press.
• Lid Line :  2 operations on the same equipment, staggered in time. Deepak Mane on the shear, Pravin Kale on the press.

Total output: 14,100 good containers from a 15,000 target. The 6% loss is fully accounted, 1% at slitting, 0.2% at coating, 0.6% at printing, 2% at punching. The system tracks every piece lost at every step. 

Quality at Every Stage 

Six quality inspection templates cover every critical checkpoint: 

1. Incoming tinplate sheet inspection (we saw this catch the defective lid sheets) 
2. Body strip after slitting with width and edge quality 
3. Epoxy coated strip with adhesion and thickness 
4. Body blank after punching with dimensions and weight
5. Circular blank with diameter and surface finish and
6. Sealed container final with leak test, seam tightness, print quality 

Outgoing inspection cleared 14,100 containers and 14,100 lids before dispatch. Nothing leaves the factory without quality sign-off. 

Delivery and Invoicing 

A partial delivery of 14,100 out of 15,000, with the remaining 900 tracked as backlog on the Sales Order. The Delivery Note generates a Sales Invoice automatically. On the purchase side, the Purchase Receipt generates a Purchase Invoice. Every transaction gets posted to the accounting ledger in real time. 

Why ERP Implementation Services Matter for Tin Container Manufacturing 

Most tin packaging factories in India run on a combination of Excel spreadsheets, paper job cards, and manual stock registers. This works until it doesn't. A rejected batch gets mixed with good material, scrap quantities don't match the dealer's weighment, an operator's efficiency drops, and nobody notices for weeks, or a customer audit asks for traceability that simply doesn't exist. 

An ERP implementation service provider solves these problems not by adding work, but by connecting the work that's already being done. The storekeeper receives material, and the system checks quality. The operator finishes a run, the system logs time and scrap. The dispatch team ships an order, the system updates stock and posts the invoice. Same actions, but now every action creates a digital record that's linked, searchable, and permanent. 

The 4L container in this demo has about 40 real operations. We showed 9 of them. The remaining 31 follow the same pattern, same screens, same quality checks, same material tracking. The system scales with your process complexity. 

The Technology 

This implementation runs on ERPNext, an open-source ERP platform with full manufacturing, quality management, stock control, and accounting modules. It's cloud-hosted, accessible from any browser or mobile device, and supports role-based access so every user sees only what's relevant to their job. 

The system is customized for tin manufacturing with: 

1. Multi-level Bill of Materials with 7 levels 
2. Strip size calculators linked to container dimensions 
3. Sheet grade and thickness tracking on item masters 
4. Punch die tool master with cavity counts and
5. Quality inspection templates with industry-specific parameters

Explore the Live Demo 

We've set up a read-only demo site that you can browse at your own pace: 

URL: https://tinpack.bharatclouds.com 

Contact us for login credentials and a guided walkthrough tailored to your specific product range. 

Get in Touch 

If you are a tin container manufacturer, metal packaging company, or sheet metal fabricator exploring ways to move beyond spreadsheets and disconnected processes, we’d be happy to show you how a fully integrated ERP system can bring greater visibility, control, and efficiency to your operations.

With years of expertise in ERP Managed services, we do ERP Implementation services for the tin manufacturing industries, including packaging, plastics and injection moulding, sheet metal fabrication, and general engineering. From initial process mapping to go-live and training, we handle the complete implementation.