1. Overview

Gestion Cartonnerie turns Dolibarr into a complete ERP for a corrugated packaging plant. It covers the entire value chain of a carton factory, from purchasing paper reels to despatching pallets of finished boxes, so that the company no longer needs any separate specialised software.

The production flow modelled by the module is the following:

·       Paper reel purchasing and reception (grade, grammage, width, supplier lot, moisture, certification)

·       Corrugator runs producing the corrugated board

·       Conversion: slitting, die-cutting, creasing, rotary die-cutting

·       Flexographic printing

·       Gluing, stitching and flat folding

·       Quality control: ECT, BCT, Cobb, RCT, Mullen burst, moisture, grammage, dimensional and visual checks

·       Palletising and finished goods stock

·       Despatch, invoicing and waste recycling

The target user is a small or medium sized corrugated packaging manufacturer producing regular slotted containers, die-cut boxes, trays, inner fitments, cardboard point-of-sale displays and pallet interlayers, which currently runs its operations on spreadsheets.

2. Module at a Glance

Item	Value
Technical name	cartonneriemanagement
Object prefix	ctn
Module number	537000
Version	1.0.0
Business objects	20
Database tables	20
Permission groups	8 (23 individual rights)
Menu entries	1 top menu + 23 left menu entries
Dashboard indicators	28 KPIs across 6 zones
Dashboard charts	6
Reports	10, each with CSV / Excel / Word / PDF export
Languages	French, English, Spanish, Italian, German
Dolibarr compatibility	16.0 and above
PHP compatibility	7.1 to 8.x
Publisher	DoliResources - www.doliresources.com
Licence	GPL v3

 

3. Functional Coverage

3.1 Paper materials

Raw material is tracked reel by reel, which is the only level at which a corrugated plant can reconcile tonnage purchased against tonnage sold.

·       Paper reels: reel reference, paper grade (Kraftliner, Testliner, Fluting, White Top, coated), grammage in g/m2, width, diameter, core, net weight, remaining weight, running length.

·       Supplier traceability: paper supplier, supplier lot number, FSC or PEFC certification, recycled fibre content, moisture at reception, cost per kilo, warehouse slot.

·       Reel status: in stock, on the machine, consumed or scrapped.

·       Paper suppliers: a dedicated record backed by a native Dolibarr third party, holding the grades supplied, average lead time, average price per ton, service rate, quality score, annual tonnage, certification and incoterm.

3.2 Corrugator and board production

·       Corrugator runs: run reference, machine, start and end date and time, shift (morning, afternoon, night), responsible operator, working width, average speed in m/min.

·       Output measurement: linear meters, surface produced in square meters, weight produced.

·       Performance: waste rate, downtime in minutes, main downtime reason, OEE of the run.

·       Corrugated boards: flute type (A, B, C, E, F, BC double, EB double, AAA triple), paper composition (outer liner / fluting / inner liner), total grammage, thickness, sheet format, unit surface, theoretical ECT in kN/m, quantity produced and available, cost per square meter.

3.3 Product catalogue

·       Packaging articles described with their FEFCO code (0201, 0203, 0300, 0427, 0713 and so on) and packaging type: regular slotted container, die-cut box, tray, lid, inner fitment, interlayer, point-of-sale display, punnet.

·       Geometry: internal length, width and height, flat dimensions, computed developed surface.

·       Printing: number of colours and printing type (direct flexo, preprint, laminated offset, unprinted).

·       Logistics data: unit weight, quantity per pallet, quantity per bundle.

·       Commercials: sale price per thousand, cost price per thousand and resulting margin.

·       Each article points at a native Dolibarr product so it can be quoted, ordered and invoiced.

3.4 Tooling

Cutting dies and printing plates represent a significant asset and a recurring source of downtime when they reach end of life unnoticed. The module tracks them individually.

·       Tool type: flat cutting die, rotary die, flexo plate, counter die, ejector, creasing cylinder.

·       Associated article, owner customer (native third party), tool manufacturer, creation date and acquisition cost.

·       Strokes performed against maximum strokes, giving an automatically computed wear rate.

·       Last refurbishment date, storage slot, rebilling flag and tool status.

·       Dashboard alerts on toolings approaching end of life.

3.5 Work orders and shop floor execution

·       Work orders linking customer, article, board, tooling, machine, and optionally the originating Dolibarr sales order and quotation.

·       Quantities: ordered, launched, produced, conforming and scrapped.

·       Scheduling: launch date, due date, actual completion date, priority, progress percentage, planned versus actual hours, actual cost and amount excluding tax.

·       Status lifecycle: planned, running, suspended, done, closed, cancelled, with automatic late-order detection.

·       Routing operations: sequence, operation type (slitting, die-cutting, flexo printing, creasing, gluing, stitching, palletising), machine, operator, input and output quantities, waste quantity, setup time and run time separated.

3.6 Printing and conversion

·       Print jobs: printing machine, number of colours, ink references and ink consumed in kilos, plates used, setup sheets lost during make-ready, printing speed.

·       Print quality: registration check, colour density measurement, proof approval.

·       Conversion operations: conversion type, machine, input and output quantities, waste rate, theoretical versus actual rate, downtime.

3.7 Quality

The quality module implements the standard corrugated test plan, with a tolerance band per test and an automatically computed conformity verdict.

Test	Unit	Purpose
ECT	kN/m	Edge crush resistance of the board
BCT	daN	Box compression test on the finished case
Cobb	g/m2	Water absorption of the liner
RCT	N	Ring crush test
Mullen burst	kPa	Bursting strength
Moisture	percent	Moisture content of paper and board
Grammage	g/m2	Basis weight check
Thickness	mm	Caliper check
Dimensional	mm	Dimensional conformity of the finished box
Visual	score	Print and appearance inspection

 

·       Each control records the measured value, the lower and upper tolerance limits, the conformity verdict, the inspector, the date and the decision (accepted, concession, scrap).

·       Non-conformities and customer claims: origin (internal, customer, supplier), severity, root cause and cause family following the 5M method, corrective and preventive actions, owner, cost of poor quality, impacted quantity, opening and closing dates.

·       Aggregated indicators: conformity rate, scrap rate, cost of poor quality, customer PPM.

3.8 Machines and maintenance

·       Machine fleet: corrugator, printer-slotters, flat and rotary die-cutters, folder-gluer, slitter, strapping machine, palletiser.

·       Machine data: type, manufacturer, year built, maximum width, nominal rate, number of colours, workshop, criticality, acquisition value, running hours.

·       Performance: OEE and operational availability rate, absorbing planned maintenance, cleaning and format changeovers.

·       Maintenance: preventive, corrective and predictive interventions, planned and actual dates, downtime, technician, parts used, cost, periodicity and next due date.

·       Dashboard alerts on overdue preventive maintenance and on machines in breakdown.

3.9 Stock, palletising and logistics

·       Finished goods stock per article and per native Dolibarr warehouse, with slot, available and reserved quantities, number of pallets, alert threshold, rotation in days and valuation.

·       Shipments and palletising: number of pallets, pallet type (EUR, EUR2, one-way), number of bundles, gross weight, pallet height, stretch wrapping, carrier, tracking number, incoterm, transport cost, despatch and delivery dates.

·       Optional link to a native Dolibarr shipment.

3.10 Waste and recycling

·       Waste tracked by origin (corrugator, die-cutting, printing, gluing, customer return) and by type (board offcuts, paper, ink, glue, film).

·       Weight in kilos per period, destination (paper recycling, internal shredding, energy recovery, landfill), recycling rate.

·       Economic valuation: buyback price per ton and resulting revenue.

·       Environmental indicators: recycling rate, share of recycled material and CO2 avoided.

3.11 Costing and commercial

·       Technical costings breaking down the price of a box: material cost per square meter applied to the developed surface, conversion cost, amortised tooling cost, printing cost, logistics cost, overheads and target margin, giving a computed price per thousand.

·       The offered price per thousand can be adjusted by the sales representative, and the costing can feed a native Dolibarr commercial proposal.

·       Costing status: to be quoted, quoted, sent, won, lost, feeding the win rate indicator.

·       Customer 360 view: segment (food, e-commerce, industry, wine and spirits, pharmaceutical, logistics), cumulated revenue, tonnage, surface produced, number of work orders, average lead time, OTIF service rate, non-conformity rate, outstanding balance and toolings held.

·       Frame contracts and call-offs: committed annual volume, consumed volume, remaining volume, negotiated price per thousand, paper index and price revision periodicity.

4. Dashboard

The dashboard is deliberately different from a standard Dolibarr home page. It is designed as an industrial cockpit using the colours of the trade: deep kraft brown, corrugated amber and recycling green on a cream paper background. The hero banner carries a repeating arc pattern evoking the flute seen on the edge of a corrugated board.

4.1 Structure

·       Hero banner with the four headline figures of the month: surface produced, tonnage, revenue and conformity rate.

·       Clickable alert tiles: reels below threshold, late work orders, non-conforming controls, overdue maintenance, toolings to refurbish, critical finished goods stock. Tiles turn green, orange or red depending on the count.

·       Six KPI zones: Production, Quality, Material and environment, Sales, Logistics, Machines and maintenance.

·       Six charts and four operational tables.

·       An in-page tab bar giving one-click access to every screen of the module.

4.2 Indicators by zone

Zone	Indicators
Production	Surface produced this month, tonnage produced, work orders in progress, late work orders, average corrugator OEE, linear meters today
Quality	Conformity rate, open non-conformities, cost of poor quality, scrap rate
Material and environment	Reel stock in tons, material yield, waste rate, waste recycling rate, recycled material share, CO2 avoided
Sales	Revenue this month, margin this month, pending costings, quotation win rate, OTIF service rate
Logistics	Pallets in stock, shipments today, late shipments, critical stock
Machines and maintenance	Machines down, overdue preventive maintenance, toolings near end of life

 

4.3 Charts

·       Surface produced over the last 12 rolling months (bar chart).

·       Production split by flute type (pie chart).

·       Monthly quality conformity rate (line chart).

·       Revenue split by customer segment (pie chart).

·       Top 10 produced articles (bar chart).

·       Load per machine (bar chart).

5. Reporting

A dedicated Reporting menu provides ten situation reports. Every report accepts a date range filter and can be exported to CSV, Excel, Word and PDF. All exports are produced in real UTF-8 so that accented characters are preserved.

Report	Content
Production	Work orders, quantities, surfaces, tonnage, scrap and scrap rate by month
Corrugator	Runs, linear meters, surface, average speed, waste rate, downtime and OEE by month
Quality	Controls and conformity rate by test type, with average measured value
Material	Reels, total and remaining weight, average cost per kilo and recycled content by grade
Machines	OEE, availability, running hours, maintenance count and cost per machine
Tooling	Strokes performed against maximum, wear rate and status, sorted by wear
Sales	Customers, revenue, tonnage, work orders, OTIF and non-conformity rate by segment
Logistics	Shipments, pallets, gross weight, transport cost and late shipments by carrier
Environment	Waste weight, recycling rate, recovery revenue and CO2 avoided by origin and type
Finance	Revenue, actual cost, margin rate, cost of poor quality and waste revenue by month

 

6. Integration with native Dolibarr modules

The module deliberately does not reimplement anything Dolibarr already provides. It links to the native modules instead:

Native module	Usage in Gestion Cartonnerie
Third parties	Customers, paper suppliers and carriers
Products and services	Every packaging article points at a native product
Commercial proposals	A technical costing feeds a native quotation
Sales orders	A work order is attached to a native customer order
Customer invoices	Invoicing of completed work orders and of tooling
Supplier orders and invoices	Paper reel purchasing
Stocks and warehouses	Finished goods stock and reel storage
Shipments	Native shipment linked to the palletising record
Projects	Packaging development projects
Agenda and events	Work order milestones and maintenance due dates
Users	Operators, inspectors, technicians and managers
ECM and documents	Cutting plans, printing proofs and material certificates

 

7. Permissions

Permissions are organised into eight functional groups. Read and write are granted by default on activation so the module is immediately usable; delete and administration are not granted by default.

Group	Scope
Material	Paper suppliers and paper reels
Production	Corrugator runs, boards, work orders, routing, printing, conversion
Catalogue	Packaging articles and tooling
Quality	Quality controls and non-conformities
Maintenance	Machines and maintenance interventions
Logistics	Finished goods stock, shipments and waste
Sales	Costings, customer 360 records and frame contracts
Reporting	Access to the ten reports (read only)

 

8. Demonstration dataset

The module configuration page provides two buttons controlling a complete demonstration dataset spread over twelve rolling months, so that every KPI, chart and report is immediately meaningful on a fresh installation.

·       Install demonstration data: creates paper suppliers, reels, corrugator runs, boards, FEFCO articles, toolings, work orders with their routing operations, print jobs, conversion operations, quality controls, non-conformities, machines, maintenance interventions, finished goods stock, shipments, waste records, costings, customer 360 records and frame contracts, together with the matching native third parties and products.

·       Remove demonstration data: purges the whole dataset, including the native objects it created and any records the user added underneath a demonstration parent, after confirmation.

·       The dataset is realistic rather than merely present: quality measurements are drawn inside their own tolerance band with an explicit small reject rate, giving a plant-level conformity around 96 percent, and all twelve months of every monthly chart are populated.

9. Configuration parameters

Parameter	Purpose	Default
Default flute type	Flute proposed when creating a board	BC
Waste rate target	Threshold above which the waste KPI turns orange	6 percent
Reel stock alert threshold	Minimum reel stock in tons	40 t
Overhead rate	Overheads applied in the costing engine	12 percent
Default target margin	Target margin applied in the costing engine	18 percent

 

10. Technical characteristics

·       All business objects extend Dolibarr CommonObject and implement create, fetch, fetchAll, update, delete, getNomUrl and getLibStatut.

·       Generic list engine with multi-criteria search, sorting, pagination and a column show/hide selector; generic card engine with tabs, creation, editing, deletion and linked records.

·       Schema self-healing on activation: missing columns are added automatically on upgrade, since Dolibarr only ever creates tables and never alters them.

·       Multi-entity aware; compatible with PHP 8; every source file passes php -l.

·       Font Awesome 5 icons only, matching the icon set shipped with Dolibarr.

·       Every user-visible translation key is module-prefixed to avoid collisions with other installed modules, and is re-asserted on each page of the module.

·       Copyright header on every source file.

11. Installation

·       Deploy the archive module_cartonneriemanagement-1.0.zip through Home, Setup, Modules, Deploy an external module.

·       Alternatively, unzip the cartonneriemanagement folder into the custom directory of the Dolibarr installation.

·       Enable the module Gestion Cartonnerie in the module list.

·       The demonstration dataset is generated automatically on first activation.

 

Gestion Cartonnerie 1.0.0 — © 2026 DoliResources — www.doliresources.com