Slit smarter.
Recover everything.
The most advanced deckle and slitting optimization engine built for paper mills. Three intelligent tiers. 180+ constraints. Continuous pattern learning. Saves ₹100K+ per month at the winder.
3-Tier
Engine
180+
Constraints
<2s
Instant Mode
₹100K+
Saved / month
The hidden cost
Every kilo of trim is a kilo of money in the bin.
A typical paper mill loses 4–6% of production to trim waste at the winder. For a 2,000 TPD mill at ₹70,000/tonne pulp + conversion cost, that's ₹56–84 crore burned every year— turning premium paper into recycled fiber at a fraction of value.
Manual deckle planning makes it worse: planners hand-build cut patterns using spreadsheets, can't evaluate alternatives, and re-plan takes 30–45 minutes whenever an order changes.
Trim waste impact · 2000 TPD mill
* Based on ₹70K/t pulp+conversion, 5% trim, 95% recovery improvement target. Actual savings depend on mill configuration.
The 3-Tier Engine
Right algorithm. Right time budget.
Three modes for three planning horizons. The engine auto-selects based on problem complexity and available time, or you can force a mode for specific scenarios.
Instant Mode
Mid-shift quick fixes
When to use
Order changed. Reel rejected. Last-minute customer call.
Method
Greedy heuristics, pre-warmed cache, demand graph traversal
QUALITY
Good (~92% of optimal)
CONSTRAINTS
Hard constraints only
Planning Mode
Shift-level planning
When to use
Morning planner meeting. Shift handover.
Method
Metaheuristic search with neighborhood exploration
QUALITY
Very good (~97% of optimal)
CONSTRAINTS
Hard + soft preferences
Full Optimization
Daily / weekly plan
When to use
Production planner builds the next-day master plan.
Method
Exact MILP solving with 180+ constraints
QUALITY
Provably optimal
CONSTRAINTS
All hard, all soft, all preferences
Sample Output
A real optimization plan.
What you actually see after a Full Optimization run. Every slit, every position, every reel — with reasoning.
Deckle width
5,260 mm
Trim
1.4%
Recovery
98.6%
SWO value
₹4.2L
Solver
MILP · 3m42s
Slitting Pattern — Deckle 5,260 mm
Active constraints honored (12 of 180+)
Constraints Catalog
180+ constraints. Eight categories.
Every rule of your mill — hard limits and soft preferences — codified, configurable, and honored on every plan.
Machine Constraints
32 constraints
- · Reel diameter min/max per machine
- · Reel weight max
- · Deckle width (active trim width)
- · Speed limits by grade
- · Knife position count + spacing
- · Turret type (single, double, triple)
- · Slitter arm reach limits
- · Crepe ratio applicable
- · OD-to-width compatibility per machine
- · Cross-grain orientation
Quality Constraints
28 constraints
- · GSM tolerance per grade
- · Brightness band per customer spec
- · Moisture limits at winder
- · Opacity floor per product
- · Tensile strength minimums
- · Smoothness range
- · Air permeability bounds
- · COBB value limits
- · Burst strength minimums
- · Ring Crush ratio thresholds
Customer Constraints
24 constraints
- · Order-specific width tolerance
- · Allowed pocket positions per customer
- · Reel weight contracted range
- · Grade substitution rules
- · Quality grade-up acceptance
- · Delivery-date binding constraints
- · Customer-specific allowance percentages
- · Approved deckle patterns
- · Forbidden trim percentages
- · Loyalty-grade priority bumps
Cost & Recovery
22 constraints
- · Trim cost per metric tonne
- · SWO recovery valuation (20× waste)
- · Set-up changeover cost
- · Reel rejection penalty
- · Quality grade-down cost
- · Storage cost (idle reels)
- · Late delivery penalty
- · Energy cost per machine-hour
- · Operator overtime premium
- · Conversion cost from reel to sheet
Operational
20 constraints
- · Shift-bound demand fulfillment
- · Machine availability windows
- · Maintenance lock periods
- · Grade-changeover sequencing
- · Chemistry change limits per shift
- · Operator skill matrix
- · Crew capacity per shift
- · Concurrent run limits per type
- · FIFO pulp consumption
- · Roll handling capacity
Process & Position
18 constraints
- · Position-specific allowances
- · OD grouping rules
- · Pocket auto-detection logic
- · Cutter routing dependencies
- · Position constraint trees
- · SWO position scoring
- · Cross-machine balance limits
- · Pattern rotation rules
- · Edge-trim minimums
- · Anti-stacking constraints
Inventory & Allocation
16 constraints
- · FEFO batch ordering
- · Reel availability windows
- · Allocated stock vs free stock
- · Customer reservation honoring
- · Quality-hold stock exclusion
- · Consignment stock rules
- · Expiry-aware allocation
- · Multi-warehouse availability
Compliance & Audit
20 constraints
- · Approval-gate for high-cost changes
- · Auditor-log every plan revision
- · RBAC-bound configuration changes
- · Customer-spec authority validation
- · Grade-substitution authorization
- · Pattern-library version locking
- · Pre-flight regulatory check
- · Plan-vs-actual tolerance triggers
Configuration
15+ tunable areas.
Configure once, then keep refining. Every knob exposed through admin UI, all changes versioned and audit-logged.
Constraint Profiles
Speed, capacity, quality, material profiles. Switch instantly between production scenarios.
Optimization Profiles
Clone, customize, set defaults. Different profiles for different shifts or product mixes.
Priority Profiles
Weighted scoring across cost, recovery, customer priority, delivery date. Tune the trade-off.
SWO Configuration
Stock Without Order parameters. Set valuation, position scoring, recovery targets.
Machine Chains
Serial machine setup, grade matrix, cross-machine routing.
Solver Settings
Tier selection rules, time budgets, gap targets, warm-start sources.
Cutter Routing
Pocket and slit priority, blade reordering, knife position constraints.
Allowance Rules
Pocket allowances, reel allowances, machine-specific tolerances.
Position Constraints
OD grouping, position-specific limits, edge constraints.
Auto-Exclusion
Product group configs, automatic exclusion rules for incompatible items.
Product Group Fields
Custom fields per product group, grouping logic, substitution rules.
Cost Configuration
Per-company cost models, per-grade overrides, currency handling.
Batch I Tolerances
Customer tolerance bands, BF compatibility, grade-substitution rules.
Pattern Library
Captured patterns, effectiveness scoring, pattern-bias weighting.
Audit Configuration
What gets logged, who can see, retention policy, signature requirements.
Use Cases
Real mill scenarios.
Four typical situations where Deckle Optimizer changes the outcome.
Case 01
Reactive: Customer Cancels at 11am
Scenario
Order for 4,800 kg of 42 GSM is cancelled at 11am. Mill has already produced 1,200 kg. Operator has 30 minutes before next changeover.
Deckle Response
Operator triggers Instant Mode. In 1.4 seconds, engine generates new plan: convert remaining production to nearest-grade SWO at valid pocket positions, reassign 800 kg to backlog order at acceptable substitution width. Operator approves and executes.
time
1.4s
recovery
95%
waste avoided
2,800 kg
Case 02
Planning: Tomorrow's Master Plan
Scenario
Production planner needs daily plan for tomorrow. 47 confirmed orders, 12 pending priority calls. Two machines, three grade families, 180+ constraints active.
Deckle Response
Full Optimization mode runs at 4:30 PM. In 3 minutes 42 seconds, engine produces optimized plan with explainability. Planner reviews active constraints, alternate patterns, recovery analysis. Drag-drop two manual overrides, approve, lock plan for production.
time
3m 42s
coverage
100%
trim pct
1.8%
Case 03
Strategic: Quoting a New Customer
Scenario
New customer wants 8 standard widths over 14 days. Need to quote tight margin without committing to losses. Sales asks production planning for trim implications.
Deckle Response
Planning Mode runs scenarios. Compare 4 acceptance patterns. Trim curve plotted across volumes. Margin floor validated. Quote sent with confidence.
scenarios
4
quote margin
+2.8%
risk
Low
Case 04
Learning: Pattern Becomes Standard
Scenario
Planner has approved the same 6-slit pattern for medium-GSM kraft 14 times. Engine has been logging it.
Deckle Response
After 10 approved runs with consistent outcomes, engine adds pattern to library with effectiveness score. Future similar demand auto-biases toward this pattern. Operator's expertise compounds into the system.
approvals
14
confidence
High
time saved
~2 hours/wk
Performance Comparison
Manual vs Deckle.
Before/after numbers from a representative 2,000 TPD mill running Deckle for 90 days.
Reports & Analytics
What you get out.
Recovery analysis, pattern effectiveness, plan-vs-actual reconciliation, trim trends. Reports that turn data into decisions.
Trim % Trend
Trim % dropped from 5.2% to 1.6% over 12 weeks after Deckle go-live.
Recovery Breakdown
SWO valued at 20× waste. Highly tuned recovery drops trim near theoretical minimum.
Pattern Library
Top 5 learned patterns. Engine biases toward high-score patterns when demand matches.
Solver Time Distribution
Last 30 days. 96% of optimizations are Instant or Planning mode — 4% need Full.
Plan vs Actual (last 7 days)
Plan accuracy > ±1% on 6 of 7 days. Thursday investigated and root cause identified.
Monthly Savings
₹4.82 Cr
Last 6 months, cumulative
Realized savings ROI: 9.2× annualized.
Integration Modes
Embedded. Standalone. API.
Choose how Deckle fits into your stack. Use it embedded in Papyrus BPApp, plug it into your existing ERP, or call it API-only.
Embedded
Bundled with the Papyrus platform. Single login, shared data, native integration with Sales, Inventory, Production.
Standalone
Deployed as independent product. Plugs into your existing ERP (SAP, Oracle, Tally, Microsoft Dynamics, custom).
API-Only
Headless integration. Send demand via REST, receive plans as JSON. Build your own UI or embed in existing dashboards.
Hosting Options
Cloud SaaS
Fully managed, Vercel/AWS hosted, auto-scaling, 99.5% SLA.
Private Cloud
Dedicated cloud tenant, customer VPC, region-locked data.
On-Premise
Customer datacenter, full control, supported via VPN.
Hybrid
API in cloud, planner UI on-prem, or vice versa.
Pre-built ERP Connectors
Connect to your existing ERP in days — not months. Standard connectors ship with mapping templates for paper-industry data models.
Implementation
From contract to ROI in 30 days.
Typical rollout. Faster for API-only integration, longer for full embedded with custom integrations.
Data discovery & onboarding
- Machine master setup
- Grade and product catalog import
- Customer specifications import
- Initial constraint profile
Configuration & calibration
- 15+ config areas set up
- Cost model tuning
- Allowance rules per machine
- Pattern library seeded with historical data
Shadow mode parallel run
- Engine runs alongside manual planning
- Daily plan comparison
- Operator training
- Edge cases flagged and configured
Go-live
- Cutover to Deckle-generated plans
- On-site planner support
- Pattern learning activated
- Performance baseline locked
Continuous improvement
- Weekly review cadence
- Pattern library grows with approvals
- Configuration refinements
- ROI tracking against baseline
Planner Workspace
Built for planners, not data scientists.
Interactive planner UI with drag-drop adjustments, live constraint feedback, alternative pattern explorer, and one-click approval.
Demand Pool
SO-2847
ABC Paper
1200mm · 4.2t
SO-2851
GHI Mills
1100mm · 3.8t
SO-2855
XYZ Pack
800mm · 2.4t
SO-2861
ABC Paper
950mm · 1.9t
SO-2867
GHI Mills
850mm · 2.1t
Slitting Canvas · 5260mm deckle
Trim 1.4% · Recovery 98.6%✓ All 12 active constraints satisfied. Plan ready for release.
Live Constraints
Every Capability
Drill into any feature.
Click any capability to drill in.
Integrations
Works with everything else.
Every Deckle Optimizer action flows into the other modules — no manual data re-entry, no reconciliation pain.
Deckle Optimizer→Sales
Demand → optimization input
Pull confirmed SO requirements
Deckle Optimizer→Inventory
Plan → reel allocation
Reserve reels for slitting
Deckle Optimizer→Production
Plan release → WO
Auto-create work order on approve
Deckle Optimizer→Finance
Plan → cost analysis
Sellable recovery vs. waste valuation
Ready to modernize your mill?
See Papyrus BPApp
in your mill.
Book a personalized demo. We'll walk through every module relevant to your operation — from Deckle optimization to GSTR-3B compliance.