From virgin pellet & masterbatch to sealed customer gaylord — one Certificate of Compliance in your customer's format — recipe, regrind ratio and substance status locked.
V5 Ultimate runs every step your medical-device, food-contact and automotive customers audit — Approved Supplier + REACH / RoHS qualification, barcode-scanned receipt of every super-sack and gaylord, gravimetric dispense of virgin resin, color masterbatch and additives against the locked recipe, extruder / MFI capture, regrind ratio tracked shot-by-shot, physical / rheological / thermal testing in the LIMS, per-customer specs, REACH SVHC and RoHS status by lot, and an auto-generated Certificate of Compliance in your customer's format at bag-off. No paper travelers, no regrind guesswork, no customer incoming-QA rejection.
Built for ISO 9001, IATF 16949, FDA 21 CFR 177 (food contact), and USP Class VI.
The same batch record — seen the way you run the plant.
For a compounder or molder supplying regulated end-markets, the small wins compound with every gaylord. Finance sees higher first-pass yield and regrind used to spec. Operations sees the next grade changeover clear the purge check on time. Quality sees a Certificate of Compliance the customer's incoming-QA and their regulator will accept without a phone call.
Higher first-pass yield on premium virgin resin and masterbatch — dispense drift squeezed, giveaway killed, regrind used to spec, and true cost per kg finally on the page.
- Per-lot actual cost: virgin resin, masterbatch, additives, packaging, regrind, labour and rework — visible in $, today.
- Lower giveaway from gravimetric dispense and MFI monitoring — no over-add of expensive masterbatch or additive.
- Fewer customer incoming-QA rejections from CoC transcription errors, wrong-substance-status entries and spec-column drift.
- Most compounders and molders see V5 pay back inside year one and keep compounding.
From the qualified virgin & masterbatch lot to the sealed customer gaylord & Certificate of Compliance — one recipe-locked thread.
Follow one compound lot. Every step below is a single screen in V5 — and the approved-supplier program, REACH SVHC / RoHS status, food-contact / USP Class VI evidence and customer-specific spec library run underneath them all.
Qualified supplier, verified virgin & masterbatch lot, substance status intact — before a pellet reaches the extruder throat.
The only recipe the line can run is the released, customer-approved version — drift from the recipe or regrind ratio is physically impossible.
The batch can't ship until every customer-spec attribute is green — and the reviewer sees every OOS in one place.
One finished compound lot, one CoC in the customer's format, one QA-signed unit — no manual retyping into the customer's CoC template.
"If a pigment supplier just flagged a REACH SVHC — which medical, food-contact and automotive customers are exposed?"
Every pallet ships with the CoC, GS1-128 SSCC, substance-status marks and a bag manifest tied to the released compound lot. When a supplier flag, a customer complaint or a REACH / RoHS substance event triggers a stop-sale, V5's lot + bag + gaylord tree paints the affected ranges and destinations — forward from the finished compound lot and backward to every input virgin resin, masterbatch, additive, regrind and packaging lot that built it. A CoC retraction with the customer recall pack drafts itself.
A pigment supplier confirms an SVHC contamination on color masterbatch lot CM-7740. V5 walks the tree — the finished compound lot that used it, the bag and gaylord ranges dispatched, the medical, food-contact and automotive customers exposed. Pull the lever to see the customer CoC-retraction pack assemble itself.
Extruder PM, grinder / pelletizer verification, dust collection & purge validation — on the same tablet as production.
Quality, REACH / RoHS substance control and Certificate of Compliance control run through every compound lot — not stapled to the record at the end.
Every quality feature in V5 — mapped to a plastics compounder & molder.
The same platform that runs pharmaceuticals and human food — set up for the way a compounder or molder actually receives, dries, dispenses, extrudes, pelletises, tests, bags-off and releases a lot under ISO 9001, IATF 16949, 21 CFR 177, USP Class VI, REACH and RoHS.
Approved Supplier Program & REACH / RoHS
Configurable per virgin resin, masterbatch, additive and pack. CoA + REACH SVHC + RoHS + food-contact / USP Class VI verified at receipt; expired qualification blocks goods-in automatically.
Gravimetric dispense & regrind by shot
Loss-in-weight feeders and gravimetric dispense verify virgin resin, masterbatch and additives to the gram. Regrind ratio is captured shot-by-shot — an OOS regrind ratio opens a deviation.
Two-signature release
Production + QA review-and-release before any blend ships. Every gate signed with a validated e-signature — identity + meaning captured.
Deviation, complaint & customer feedback
One workflow from issue raised through root cause, action, verification and close. Linked to the affected blend, workstation, operator, supplier and customer — customer complaint routes to the correct account team.
Recipe & CoC lockdown
Recipes are immutable, rev-locked and tied to the customer's current spec. Current-rev customer CoC template pinned per lot — the CoC engine refuses to render a superseded spec.
Supplier scorecards & re-qualification
On-time delivery, CoA quality, REACH / RoHS status, food-contact / USP VI statements, deviation rate and audit findings rolled into a live supplier score. Expired qualifications block goods-in automatically.
REACH SVHC & RoHS chain of custody
REACH SVHC, RoHS, 21 CFR 177 food-contact and USP Class VI status carried lot-by-lot from receiving through extrusion, pelletising, packaging and shipping — with substance mass-balance evidence enforced at each step.
Auto customer-CoC in your customer's format
The CoC engine renders results into the customer's preferred template — their column order, method IDs, spec limits, substance status and letterhead — from released lot data at bag-off.
Retain samples & aging studies
Retain samples booked into the retain library per lot with location, disposition and expiry. Aging studies scheduled per grade — MFI, tensile, colour ΔE and UV / thermal aging pull-points tied to the recipe.
Live on your extruders, feeders, pelletizers and bag-off lines — no rip-and-replace.
We connect at the level your engineers and QA team expect — OPC UA, Modbus, MQTT, REST, EDI, file drops, SQL. Most compounders are live on day one with the extruders, side-feeders, pelletizers, gravimetric feeders, colour dosers, dryers, metal detectors, checkweighers and bag-off lines already installed.
Extrusion, dispense & pelletising
OPC UA and Modbus links to Coperion, Leistritz, KraussMaffei-Berstorff, JSW, Steer twin-screw compounding extruders and side-feeders; K-Tron, Coperion, Schenck, Acrison, Movacolor loss-in-weight and gravimetric feeders; Gala, BKG and Rieter underwater and strand pelletizers. Screw speed, barrel temperature, torque, melt temp / pressure and dispensed mass logged straight to the lot.
Screens, magnets, metal detect & checkweigh
Screen-pack change registers, Bunting and Eriez magnets; Mettler-Toledo Safeline, Loma, Anritsu, Ishida metal detectors and checkweighers. Reject events, test-piece verifications and giveaway data streamed to the lot — a failed verification hard-stops the line.
Bag-off, gaylord / octabin fill & label
Concetti, Premier Tech, Haver & Boecker, Statec Binder bag-off and gaylord / octabin fillers; Videojet, Domino, Markem-Imaje, Zebra thermal-transfer and print-and-apply labellers. Current-rev customer bag label and CoC reference pinned per lot at the line.
Lab instruments & LIMS
Melt flow indexer, tensile tester, DSC / TGA, FTIR, ICP-MS, LC-MS/MS, moisture (Karl Fischer), colour spectrophotometer, density balance. Direct connectors for Waters, Agilent, Thermo Scientific, PerkinElmer, Mettler-Toledo, HunterLab and Malvern Panalytical.
ERP, WMS & customer portals
SAP, NetSuite, Microsoft Dynamics 365, Oracle, Infor, IQMS, Plex. Customer EDI, ASN and customer-CoC delivery per customer preference — email, SFTP, portal upload or API. IATF 16949 PPAP submission packs assembled from released lot data.
BI & data warehouse
Power BI, Tableau, Looker, Snowflake, Databricks. Direct SQL access to your tenant — your data, your queries, your validated reports.
ISO 9001, IATF 16949, 21 CFR 177, USP VI, REACH & RoHS — at the data layer.
The records build themselves as the blend is executed. When the FDA FSMA inspector, an IATF 16949 PPAP auditor, an ISO 9001 auditor, an FDA food-contact investigator or a customer-audit team walks in, the evidence pack is one click — not a week of re-assembly.
Fixed-price, named team, one product family live before you pay for the next.
- Week 1–4·step 01Discovery & floor scan
We walk one product family with your team — recipes, customer spec library, CoC templates, regrind rules, REACH SVHC / RoHS status, food-contact / USP VI statements, existing ERP and WMS fields. Out: a fixed scope and price.
- Week 5–9·step 02Configure & integrate
Material master, recipes, per-customer specs, LIMS methods (MFI, tensile, thermal, FTIR ID, REACH screen), customer CoC templates, extruder / feeder / pelletizer / metal-detector / bag-off integrations and ERP feeds loaded.
- Week 10–13·step 03Pilot & train
One product family live in pilot. Three-shift operator training on the floor with the actual UI — not slides. UAT signed by QA, production and operations.
- Week 14–16·step 04Go live & hyper-care
Cut over. Two weeks of hyper-care with your named delivery team on-site. KPIs published on the wall before we leave.
The first six questions on every plastics compounding RFP.
How does V5 auto-generate a Certificate of Compliance in the customer's preferred format?
How does V5 handle FSMA Preventive Controls and FSVP for imported ingredients?
How does V5 track regrind and virgin ratios by shot, and enforce the customer spec?
Will V5 talk to our extruders, side-feeders, pelletizers, metal detectors and bag-off lines?
We toll-compound for multiple customers on one extruder line — how does V5 keep them separate?
What about IT — validated change control, SOC 2 and GFSI / certifying-body audit prep?
Book a 30-minute walkthrough with a plastics & resins specialist.
We'll show a live self-building compound-lot record, recipe lockdown, gravimetric dispense and extruder-parameter capture, regrind-by-shot tracking, MFI / tensile / thermal in the LIMS, two-signature release, auto CoC generation in your customer's format at bag-off and a mock REACH SVHC traceback — on a workspace seeded for a working plastics compounder.
Fixed-price go-live · No platform lock-in · Onboard in 10–16 weeks