Comfort, Manufactured Consistently

Executive Summary

Foam manufacturing is process chemistry feeding a converting business: chemical inputs become blocks, blocks become cut products, and everything is measured in densities, dimensions and yields before it reaches dealers and institutional buyers.

With TEKROI as implementation partner, Realxwell runs that flow on SAP Business One: batch production from chemicals to blocks, cutting and conversion with yield control, grade- and dimension-wise inventory, and channel sales on one core.

About Realxwell

Realxwell is a Hyderabad-based foam products manufacturer serving dealer and institutional markets.

The Challenge

Two-stage manufacturing hides its losses between the stages:

• Chemistry to block — batch outcomes vary; density and quality results needed to trace back to inputs and conditions.
• Block to product — cutting yield decides margin, and offcut accounting decided whether it was known.
• Grade-and-dimension inventory — the same foam in many densities and sizes multiplied stock complexity.
• Channel terms — dealers and institutional buyers on different pricing and credit.

The Solution

TEKROI implemented SAP Business One across both manufacturing stages and the market:

Batch Production

• Chemical-input batch production with density/grade outcomes recorded against each batch.

Conversion & Yield

• Cutting and conversion orders with yield and offcut visibility — block to product accounted.

Inventory

• Grade-, density- and dimension-wise stock across plant and depots.

Sales & Finance

• Dealer and institutional pricing and credit, with margins by product and channel on live data.

Implementation Journey

TEKROI’s fixed-scope methodology took the project from assessment to go-live through eight stages: assessment, blueprint, configuration, customization, data migration, training, go-live and ongoing support.

Results

• Both stages accounted — from chemicals to blocks to cut products, yields are facts, not estimates.
• Offcuts on the record — conversion losses are visible where they occur.
• Inventory in the business’s own language — grades, densities and dimensions, accurately.
• Channel margins clear — dealer and institutional business each on its own numbers.

Why This Story Matters

Multi-stage process manufacturers leak margin between their stages. Realxwell shows SAP Business One sealing those seams in a foam business — a pattern any converter will recognize.