EXAMPLE OF GOOD PRACTICE
We expect to achieve the desired results at Makoter. Trace BS solutions provide us with complete control over production – the entire process from film extrusion, through printing, to bag manufacturing allows full traceability of every product. It provides real time data on costs, waste, and productivity.
Challenges:
- PCR-based films – poor extrusion processing, low printing quality, difficult bag manufacturing – resulting in high scrap rates.
- Lack of LOT traceability (from granulate → to finished bag).
- Limited machine downtime control.
- Manual inventory management and discrepancies with the ERP system.
- Difficult productivity analysis.
Solution:
- Trace MES - control of extrusion, printing, assembling, cutting, and recycling processes.
- Trace WMS - optimization of the 2,470 m2 warehouse.
- Trace Quality - digital quality controls in all stages of the process: extrusion, printing, packaging, cutting.
- Trace Attendance & Access – monitoring of attendance and access movements.
- Trace Maintenance – machine maintenance management.
Results:
- +15 % increase in OEE (Overall Equipment Effectiveness),
- –10 % reduction of scrap across all production units,
- 100 % LOT traceability from granulate to finished product pallet,
- inventory aligned with ERP (deviations < 2%),
- accurate calculation of product level costs.
About the Makoter company
A family-owned company with a tradition dating back to 1981, Makoter d.o.o. is one of the leading Slovenian manufacturers of polyethylene packaging. With more than 100 employees, the company processes 6,000 tons of material annually and supplies retail chains, the food industry, and distribution centers across Europe. Its portfolio includes a wide range of products—from classic handle bags, rolled bags, and industrial bags to specialized films for automated packaging. The company exports to 10 countries, with exports accounting for 80% of its revenue.
- Founded in 1981
- 2.470 m2 of warehouse space
- 6.000 tons of annual processing
- 80% export share
Production and logistics- complexity that requires digital integration
Makoter’s production program integrates extrusion, flexographic printing, and converting technologies. Each stage requires precise adjustments: temperature, pressure, speed, and film tension. The printing lines use up to 8 colors, which means thousands of settings per production batch. At the same time, customers demand full LOT traceability and compliance with BRC / IFS standards.Manual process control was time consuming and carried a high risk of errors.
Challenges before implementing the Trace BS solution
— Repeated errors across all production departments.
— Undetected scrap and weak product control in all stages of production.
— Unreliable data on granulate and regranulate consumption.
— Difficulties in identifying the root causes of machine downtime.
— Manual management of film and finished goods inventory.
— No productivity analytics per work order.
— Physical inventory did not match the ERP records.
— No performance based reward system.
Digital transformation and the implementation of the comprehensive Trace ecosystem
Collaboration with Trace BS began in 2025. To date, they have gradually implemented:
• Trace MES
• Trace WMS
• Trace Quality
• Trace Attendance & Access
• Trace Maintenance
Trace MES monitors all production steps in real time: from extrusion (film thickness, granulate consumption) and printing (register quality) to final converting (number of welds, temperatures). Trace WMS has optimized the storage of raw materials and finished goods across 2,470 m2 — every pallet is tracked by LOT identification and exact location. Trace Quality has digitalized laboratory testing (tensile strength, puncture resistance, visual inspection) and linked the results with production batches. Trace Maintenance enables planned machine maintenance and detailed recording of failures, reducing unplanned downtime by 15%.
What has changed: production today
With MES and the connected systems, Makoter has achieved full transparency and control:
• accurate costing at the product level (including granulate, inks, labor hours, waste),
• instant identification of machine issues (alarms triggered by deviations in film thickness),
• automated productivity reports – OEE, availability, quality,
• electronic quality checks via tablets at the production line, integrated with the laboratory,
• digital, paper free work orders, with worker instructions displayed on screens.
Measurable results that speak for themselves
Overall equipment effectiveness — from extrusion to final product packaging.
Less discarded film thanks to immediate error detection.
Enabled by the Trace Maintenance system and timely interventions.
From incoming granulate to the final pallet.
Physical s>tock vs. ERP records (previously >10%).
SMED supported by MES and standardized machine settings.
Our greatest achievement is not only reflected in the numbers, but in the trust — both from our customers and our employees. We now have a tool that allows every operator to see the impact of their work on the final product. Trace BS has become part of our everyday life.
Looking ahead: digitalization as a continuous process
At Makoter, the system is being further enhanced by connecting all machines in production into a closed feedback loop and introducing an energy management module. They also plan to integrate the system with the HR information platform to enable advanced employee incentives based on OEE and quality. In the coming years, they aim to leverage all collected data to establish integration with artificial intelligence, enabling even greater optimization of the entire production process.
Why Makoter recommends Trace BS?
• Comprehensive transparency – from order to delivery,
• Solution adaptability to the specific requirements of plastic processing,
• Reduced response time in handling complaints (instant access to batch history),
• Expert support and joint development of new functionalities,
• Tangible improvement in competitiveness on demanding markets.
To every manufacturer who is still hesitating, our message is clear: digitalization is not a cost — it is the best investment. The competition will not wait.
Are you thinking about digitizing your warehouse or logistics processes?
If you are facing similar challenges as described in this case study, we can help you design and implement a solution tailored to your business. Contact us for professional consultation:
Additional information about the Trace BS solutions implemented at Makoter d.o.o.:
- Trace MES
- Trace WMS
- Trace Attendance & Access
- Trace Quality
- Trace Maintence
