In corrugated box manufacturing, wastage is part of production.

Trimming, die-cutting, joints, printing setup and other production activities can create material loss. Even a small change in the wastage percentage can affect the box weight, material cost and final quotation price.

When wastage is maintained in Excel or changed manually for every quotation, controlling the actual cost becomes difficult.

This is where ERPNext packaging software can help.

Thirvusoft implemented a controlled wastage calculation process inside ERPNext so that every quotation starts with the approved wastage for that product.

The Challenge: Wastage Was Affecting Packaging Costing

The packaging manufacturer faced several common problems:

1. Different wastage percentages were used for the same product.
2. Sales users could reduce wastage to make a quotation cheaper.
3. Wastage calculations were maintained outside the ERP software.
4. Multiple wastage stages were combined into one estimated percentage.
5. Management could not easily identify who changed the wastage.
6. A change in wastage could directly affect the box weight and quotation rate.

The result was inconsistent packaging costing and reduced control over margins.

The Solution: Controlled Wastage Calculation in ERPNext

Thirvusoft configured the ERPNext quotation workflow so wastage becomes part of the product's costing logic rather than a number users enter freely.

1. Wastage Built Into the Formula

The ERPNext Formula Builder allows different wastage stages to be included in the calculation.

For example:

Wastage 1 → Sheet Trimming

Wastage 2 → Die Cutting

Wastage 3 → Printing Setup

This allows the packaging manufacturer to represent different material-loss stages instead of using one guessed percentage.

2. Standard Wastage for Every Product

Each packaging item can have its approved standard wastage.

When the item is added to a quotation, ERPNext automatically brings the configured wastage into the weight and costing calculation.

This means the same product starts with the same standard calculation every time.

No copying from old Excel files.

No remembering percentages manually.

3. Wastage Automatically Affects Weight and Price

The wastage percentage is connected to the packaging weight calculation.

The flow becomes:

Product → Standard Wastage → Weight Calculation → Paper Cost → Quotation Price

If the wastage changes, the calculated weight and costing can change accordingly.

This gives the estimator a clear connection between material wastage and product cost.

4. Only Authorised Users Can Change Wastage

Not every salesperson should be able to reduce a product's standard wastage.

In the quotation settings, management can define Wastage Edit Users.

Authorised users can adjust wastage for a specific quotation when there is a genuine business reason.

Other users see the value as read-only.

Most importantly, the change applies only to that quotation.

The original product's standard wastage remains unchanged.

The Connected Packaging ERP Flow

Formula Builder → Item Standard Wastage → Quotation → Authorised Change → Weight Calculation → Rate → Final Price

This creates a controlled packaging quotation process without removing flexibility from authorised users.

Benefits of ERPNext Wastage Management

✓ Standard wastage is maintained for every packaging product.

✓ Sales users cannot freely reduce wastage to lower the quotation.

✓ Multiple wastage stages can be handled separately.

✓ Wastage automatically connects with weight and costing.

✓ Authorised users can make deal-specific changes.

✓ Product master values remain protected.

✓ Packaging quotations become more consistent.

✓ Material cost and profit margins are easier to control.

Wastage Control Is Margin Control

For packaging manufacturers, material is one of the biggest components of product cost.

A small change in wastage can therefore affect the corrugated box weight, material consumption, costing and selling price.

Instead of keeping wastage percentages in spreadsheets, ERPNext can make them part of a controlled quotation workflow.

With the right configuration, the system provides:

Standard wastage → Controlled changes → Accurate costing → Better quotation control

ERPNext Packaging Solutions in Coimbatore

Thirvusoft is an ERPNext implementation and customisation company in Coimbatore, helping manufacturing businesses connect product costing, inventory, production and sales processes in one ERP system.

For packaging manufacturers, Thirvusoft can customise ERPNext for corrugated box costing, GSM calculation, weight calculation, wastage management and quotation automation.

Book a Free ERPNext Demo

If your packaging quotations still depend on Excel for wastage calculation, box costing or weight calculation, Thirvusoft can help you move the process into ERPNext.

📞 Book Your FREE ERPNext Demo Today

Call / WhatsApp: +91 63790 44767

🌐 www.thirvusoft.com

📍 Peelamedu, Coimbatore