# zappy.day

> zappy.day is a manufacturing technology platform by Next Page Technologies (Hyderabad, India). It builds technology for manufacturers, with deepest focus on corrugated box manufacturers, packaging machinery manufacturers, die makers and die-cutting units, and gum and adhesive manufacturers. It also serves other packaging businesses and manufacturers outside packaging. Goal: help factories reduce wastage, grow profit, run smoothly with fewer problems, and win more business.

Key facts:
- Built by: Next Page Technologies Pvt Ltd (https://nextpagetechnologies.com), Founder & CEO Reddy Prasad Puligundla
- Location: Hyderabad, India. Serves India, Australia, USA and other countries
- 16+ years building software
- 200+ projects delivered
- ₹1–100+ Cr client turnover range
- 5+ countries with clients
- Formerly known as ERPBro
- Contact: +91 81870 30758 (call/WhatsApp), prasad@nextpagetechnologies.com

## Solutions
- [zappy ERP](https://zappy.day/solutions/zappy-erp): One system for enquiry, costing, purchase, planning, production, quality, stock, dispatch, payroll and collections. Customised to fit how your factory actually runs.
- [GrowthAgent](https://zappy.day/solutions/growth-agent): Finds the right buyers for what you make, reaches them, and follows up every enquiry until it is closed, so your sales team spends time only on serious buyers.
- [Logistics Planner](https://zappy.day/solutions/logistics-planner): Plans loads, vehicles and routes so trucks go out full and customers get material on the promised day, with proof of delivery.
- [Workflow Automation](https://zappy.day/solutions/workflow-automation): Approvals, alerts, reminders and reports that happen on their own on WhatsApp and email, so things move even when nobody is chasing.
- [Business Analytics](https://zappy.day/solutions/business-analytics): Your factory's key numbers on your phone: sales, production, wastage, margin, receivables and cash, so decisions are made on facts, not feelings.
- [AI Solutions](https://zappy.day/solutions/ai-solutions): AI that does useful factory work: reads purchase orders, predicts demand and paper needs, suggests prices, spots unusual wastage, and answers questions about your business.
- [Manufacturing Security](https://zappy.day/solutions/factory-safety-ai): Uses the CCTV cameras you already have to spot safety violations and visual defects in real time, and alerts the right person before an accident or a rejection.
- [Custom Software](https://zappy.day/solutions/custom-software): Your own software, mobile app or integration, built around your process by the team behind zappy.day, with 16+ years of building software for businesses.

## Industries
- [Corrugated Box Manufacturers](https://zappy.day/industries/corrugated-box): 3-ply, 5-ply and 7-ply box plants, sheet plants and corrugator lines. Reel stock, box costing, deckle planning, wastage, quality and dispatch.
- [Packaging Machinery Manufacturers](https://zappy.day/industries/packaging-machinery): Makers of corrugation, printing, die-cutting, folder-gluer and packing machines. Projects, BOMs, parts, assembly, testing and milestone billing.
- [Die-cut & Die Makers](https://zappy.day/industries/die-cutting): Die makers and die-cutting units. Many small custom jobs, drawing approvals, rule and rubber stock, fast turnaround and job costing.
- [Gum & Adhesive Manufacturers](https://zappy.day/industries/adhesives-gum): Corrugation gum, starch adhesives, lamination and pasting adhesives. Batch production, raw material, quality consistency, dealers and credit.
- [Other Packaging Manufacturers](https://zappy.day/industries/packaging-other): Mono cartons, printing & converting, flexible packaging, labels, paper mills, paper bags, pallets and plastic packaging.
- [Other Manufacturers](https://zappy.day/industries/other-manufacturing): Engineering & fabrication, plastics, food processing, chemicals, textiles, auto components and more. Same problems, same fixes.

## How it's made (stage-by-stage manufacturing processes, with interactive 3D)
### [Corrugated box plant](https://zappy.day/how-its-made/corrugated-box)
1. Paper reels & raw material: Kraft reels arrive by GSM, BF, deckle and supplier. The store keeper checks weight, moisture and grade, tags each reel and stacks it. When a job is planned, the right reels are pulled to the reel stands. Common problem: Register says 40 reels of 120 GSM, the godown has 32. Wrong GSM or BF gets loaded to keep the corrugator running, and quality or margin takes the hit. zappy.day: Every reel is barcoded with GSM, BF, deckle, weight and supplier. Stock is reel-wise and live, consumption is posted per job, and reorder alerts come before the stand is empty.
2. Corrugation: The single facer forms the flute and glues it to the liner. The web travels over the bridge, then the double backer adds the second liner on hot plates. Starch gum, steam and speed must stay in balance. Common problem: Wrong deckle choice, splices, warp and set-up changes create trim and process waste. It is rarely measured by shift, so nobody knows the true number. zappy.day: Deckle planning picks the reel width that wastes least for the day's jobs. Trim and process wastage are entered per shift on mobile, and the owner sees it the same evening.
3. Slitting, scoring & sheet cutting: The slitter-scorer cuts the board to width and adds crease lines. The cut-off knife cuts sheets to length, which are stacked and counted for the job. Common problem: Over-production "just in case", miscounts and sheets cut to the wrong size for the next stage. zappy.day: Job card with exact sheet size and quantity, with produced vs planned shown live. Extra sheets go to stock and are offered on the next matching order.
4. Flexo printing: Sheets pass through flexo print units, one colour per unit. Plates, ink viscosity and registration are set per job, and the first sheet is approved before the run. Common problem: Long make-ready, ink wastage, colour mismatch and rejection because the approved artwork version was not at the machine. zappy.day: Artwork version, plate and ink details stay on the job card. First-piece approval is recorded with a photo, and make-ready time is tracked by job.
5. Slotting & die-cutting: Slotters cut the flaps for regular boxes. Special shapes go through a rotary or platen die-cutter using a die made for that box. Common problem: The die can't be found or is damaged, set-up takes too long, and the machine waits for the next job card. zappy.day: A die register with location and condition. The machine-wise job queue is planned so the next job, die and sheets are ready before the current one ends.
6. Folding & gluing: The folder gluer folds the blank and glues or stitches the joint at high speed. Boxes come out flat and are counted into bundles. Common problem: Glue failures found at the customer, wrong bundle counts and boxes that are not tracked against the order. zappy.day: Output per job entered at the machine, with bundle counts and labels printed from the system, so dispatch knows exactly what is ready.
7. Quality check: Boxes are checked for dimensions, print, BCT (compression), burst strength, GSM and moisture against the customer's specs. Common problem: Tests aren't recorded, so when a customer complains there's no proof of what was supplied, and the debit note is accepted. zappy.day: QC results are recorded against each job and batch. A test report can be shared with the customer in one click, and repeat failures show up in reports.
8. Dispatch & collection: Bundles are palletised, loaded by forklift, and sent with an invoice, delivery challan and e-way bill. Then the wait for payment begins. Common problem: Half-empty trucks, no proof of delivery, invoices sent late, and payments that drift to 90 to 120 days. zappy.day: Dispatch plan with documents generated together and proof of delivery captured on mobile. Invoices go out the same day, and automatic payment reminders follow on WhatsApp.

### [Packaging machinery manufacturer](https://zappy.day/how-its-made/packaging-machinery)
1. Design & bill of materials: Engineers turn the order specification into drawings and a bill of materials: hundreds of made, bought-out and standard parts per machine, often with a customer-specific variant. Common problem: BOMs live in Excel. Revisions are not shared with purchase and the shop floor, so the wrong version gets made or bought. zappy.day: Machine-wise BOM with versions, linked to the sales order. Changes flow to purchase and production automatically.
2. Stores & purchase: Stores issue parts against each machine. Purchase orders bought-out items like motors, gearboxes, PLCs and bearings, often with long lead times. Common problem: One long-lead part is noticed late, and a 95% complete machine waits weeks. Meanwhile stock that isn't needed piles up. zappy.day: A shortage list is generated from the BOM against stock and open POs, so long-lead items are ordered on day one. Parts are issued against each machine.
3. Machining: CNC machines and lathes make shafts, rollers, gears and plates to drawing tolerances. Each operation needs time, tooling and an operator. Common problem: Jobs are picked by whoever shouts loudest. Machine hours per part are unknown, so outsourcing decisions are guesswork. zappy.day: Job cards per part and operation, with planned vs actual time. A machine-wise load view shows what to make in-house and what to outsource.
4. Fabrication & welding: Frames, side plates and guards are cut, bent and welded, then ground and painted. Common problem: Steel consumption and labour hours per frame aren't tracked, so project cost overruns stay hidden. zappy.day: Material issued against each machine, and labour hours captured by job, giving project cost as it happens, not after delivery.
5. Assembly: The machine is assembled stage by stage: frame, rollers, drives, electricals and guards. A crane moves the heavy sub-assemblies. Common problem: Nobody can say exactly how far each machine has progressed. Customers keep calling, and the delivery date keeps moving. zappy.day: A stage-wise assembly checklist for each machine, with progress visible to the owner and sales. Delays are flagged with a reason.
6. Testing & trial: The finished machine is run with real material at rated speed. Settings and test results are noted, often with the customer watching. Common problem: Test records are on paper, and punch-list items are forgotten until the customer finds them on site. zappy.day: A test checklist and punch list per machine, with sign-off before dispatch. The record stays linked to the machine's serial number.
7. Dispatch & milestone billing: The machine is crated, documented and shipped. Payment comes in milestones: advance, dispatch, and installation. Common problem: Milestone invoices are raised late or forgotten. Cash is stuck while the next machines are being financed. zappy.day: Milestones are linked to project stages: when a stage closes, the invoice is ready and reminders go out automatically.

### [Die maker](https://zappy.day/how-its-made/die-cutting)
1. Drawing & customer approval: The customer sends a box layout. The designer prepares the die drawing with cut and crease lines, bridges and ejection, then sends it for approval. Common problem: Approvals come as a thumbs-up on WhatsApp. Later nobody is sure which version was approved, and the wrong one gets made. zappy.day: Drawing versions are saved with the job. The approval is recorded against a specific version, date and person, and production can only start on the approved one.
2. Laser cutting the board: The approved drawing is laser-cut into plywood so the steel rules can sit in the slots exactly. Common problem: The laser runs whatever comes first. Rush jobs jump the queue, and promised times are guesses. zappy.day: A laser job queue with estimated cutting time per job, so delivery promises are based on the real load.
3. Rule bending: Cutting and creasing rules are bent to shape, by auto-bender or by hand, and cut to length. Common problem: Rule consumption per die isn't known, so job cost is underestimated and offcuts pile up. zappy.day: Rule metres used are logged per job, along with consumables, so each die is costed properly.
4. Rule fixing: Rules are hammered into the laser-cut slots, with nicks and bridges set so the cut sheet holds together. Common problem: Everyone works on everything. Nobody can see which job is at which stage, so every customer call becomes urgent. zappy.day: Stage tracking (design, laser, bending, fixing, rubbering, trial) for every job on one screen.
5. Rubbering: Ejection rubber of the right hardness is glued along the rules so the sheet releases cleanly after each cut. Common problem: Rubber of the wrong hardness, and rubber stock that is never counted until it runs out. zappy.day: Rubber and board stock tracked with minimum levels, and the material spec saved on each job.
6. Trial cut & QC: The die is trial-cut on a press with the customer's board to check cut, crease and ejection before delivery. Common problem: Problems are found at the customer's machine, and the die comes back for rework. zappy.day: A trial result with photo is recorded per die, and the customer is notified automatically when it is ready.
7. Delivery & repeat orders: The die is packed and delivered. The same die design is often reordered months later. Common problem: Old die details are hard to find, so repeat dies are redone from scratch, and many small invoices stay unpaid. zappy.day: A searchable die library by customer and box, with outstanding by customer and polite automatic reminders.

### [Gum & adhesive plant](https://zappy.day/how-its-made/adhesives-gum)
1. Raw material store: Starch, caustic, borax, resins and additives are received, checked and stored. Prices change often, and quality varies by supplier. Common problem: Stock is counted by eye, so material runs out mid-batch or is over-bought when prices are high. zappy.day: Material stock with minimum levels and supplier-wise rates. Consumption is posted automatically from each batch.
2. Batch weighing: Each batch is weighed out exactly as per the formula for that product grade. Common problem: Formulas sit in one person's notebook. Small weighing errors change the product, and batch cost isn't known. zappy.day: Controlled formulas by grade, with batch sheets printed from the system and actual weights recorded. Batch cost uses current material rates.
3. Cooking & mixing: Materials go into the tank in sequence with water and heat. The agitator runs for a set time, and temperature and time decide the final behaviour. Common problem: Time and temperature aren't logged, so when a batch behaves differently nobody can tell why. zappy.day: Batch log with start, end, temperature readings and operator. Every batch gets a number that follows it to the customer.
4. Viscosity & lab check: Samples are tested for viscosity, solids and gel point before the batch is released. Common problem: Results stay in a lab register, and an out-of-range batch can still be filled and dispatched. zappy.day: Lab results are entered per batch, and filling is allowed only after the batch passes. Trends show drift before complaints start.
5. Filling & labelling: The batch is filled into drums, cans or bags, labelled with product, batch number and date, and moved to finished goods. Common problem: Containers aren't linked to the batch, filled quantity isn't reconciled, and returnable drums go missing. zappy.day: Labels with batch codes printed from the system and filled quantity reconciled against the batch. Returnable containers are tracked by customer.
6. Dealer dispatch & credit: Orders come from dealers and direct customers by phone and WhatsApp, and material goes out by route. Common problem: Material keeps going to dealers who haven't paid the last three bills, and cash gets stuck in the market. zappy.day: Dealer credit limits with an automatic dispatch hold, scheduled payment reminders on WhatsApp, and dealer-wise outstanding on the owner's phone.

### [Manufacturing plant](https://zappy.day/how-its-made/other-manufacturing)
1. Raw material: Material is received, inspected, stored by location and issued to production against work orders. Common problem: Stock mismatch, over-buying and stock-outs that stop production. zappy.day: Location-wise stock, issues against each work order, and reorder alerts.
2. Machining & processing: Machines convert material into parts. Each machine has a plan, an operator and a setup. Common problem: Idle machines, unplanned breakdowns and scrap that is never measured. zappy.day: Machine-wise plans, downtime reasons and scrap captured on mobile, with utilisation shown daily.
3. Assembly: Parts and sub-assemblies come together into the finished product on a line or at stations. Common problem: Missing parts stop the line, and work-in-progress is invisible. zappy.day: Work orders with part availability checked in advance and WIP visible by stage.
4. Quality check: Products are inspected against specifications before packing. Common problem: Rejections are found by the customer, and there are no records to find the cause. zappy.day: Inspection results per batch, with rejection reasons and trends.
5. Packing & dispatch: Goods are packed, loaded and sent with documents. Then accounts follow up payment. Common problem: Late dispatch, missing documents and slow collections. zappy.day: Dispatch planning, same-day invoices and automatic payment reminders.


## Customers (references)
- Sreenidhi Raja Packing Solutions Pvt. Ltd., Tirupati
- Sri Anjanaya, Chetlapotharam, Hyderabad
- Sri Sai Packages, Hyderabad

## Product status
- Available: zappy ERP (end-to-end manufacturing operations, customised per business), Workflow Automation, Business Analytics, AI solutions, Custom software
- In development: GrowthAgent, Logistics Planner, Manufacturing Security (CCTV)

## Case studies (representative scenarios)
- [A 5-ply box plant losing lakhs to wastage nobody could see](https://zappy.day/case-studies/box-plant-wastage)
- [Quoting on old paper rates and losing margin on every new order](https://zappy.day/case-studies/box-costing)
- [Machines 95% ready, waiting for one missing part](https://zappy.day/case-studies/machine-maker-projects)
- [Fifty jobs a day and approvals lost in WhatsApp](https://zappy.day/case-studies/die-maker-approvals)
- [Dealers kept ordering while old bills stayed unpaid](https://zappy.day/case-studies/adhesive-credit)
- [Two units, one owner, and every decision waiting for him](https://zappy.day/case-studies/owner-dependency)
- [CCTV everywhere, but watched only after an accident](https://zappy.day/case-studies/cctv-safety)
- [Paying for IndiaMART leads that nobody called back](https://zappy.day/case-studies/indiamart-leads)

## Tools
- [Factory Profit Leak Calculator](https://zappy.day/profit-calculator): estimates yearly money recoverable from wastage, pricing, collections and freight using conservative assumptions.

## FAQ
Q: What is zappy.day?
A: zappy.day is a manufacturing technology platform by Next Page Technologies, Hyderabad. It combines an ERP built for corrugated box and packaging factories with B2B lead generation (GrowthAgent), a logistics planner, workflow automation, business analytics, practical AI and CCTV-based safety and defect detection. It helps manufacturers reduce wastage, control costs, deliver on time, collect payments faster and get more buyers.

Q: Which manufacturers do you work with?
A: Corrugated box manufacturers, packaging machinery manufacturers, die makers and die-cutting units, and gum and adhesive manufacturers are our core focus. We also work with other packaging businesses (mono cartons, printing and converting, flexible packaging, labels, paper) and with manufacturers outside packaging such as engineering, plastics, food processing, chemicals and textiles.

Q: We are not tech people. Will my team be able to use it?
A: Yes. Screens are simple and built for supervisors, store keepers and operators, not IT people. Most daily entries are done on a mobile phone. We train your team on the floor, in the language they are comfortable with, and stay with you until the system is part of the routine.

Q: How long does it take to go live?
A: It depends on what you start with. A single area like box costing, an owner dashboard or payment reminders can go live in 2–4 weeks. A full ERP from sales to dispatch typically takes 6–12 weeks, done in phases so the factory never stops.

Q: How much does it cost?
A: It depends on your factory size, number of users and which modules you need. We first understand where your factory is losing money, then propose a plan where the expected savings are clearly larger than the cost. Talk to us for a quote specific to your factory.

Q: Do we have to replace Tally or our current software?
A: Not necessarily. Many factories keep their accounting software and use zappy.day for everything that happens before and after the invoice: costing, stock, production, wastage, dispatch and collections. We check what you use today and recommend the simplest route.

Q: Is our data safe?
A: Your data belongs to you. We use secure cloud hosting, role-based access so each person sees only what they need, and regular backups. We are happy to explain the setup to your team or auditor.

Q: What return on investment can we expect?
A: We only promise what we can measure. Typical areas where factories recover money are material wastage, wrong pricing, slow collections, freight and time lost in follow-ups. Use our Profit Leak Calculator for a conservative estimate, then we validate it with your real numbers during a factory visit.

Q: Do you visit the factory?
A: Yes. We prefer to understand your process on the shop floor before suggesting anything. Visits can be arranged across India, and we also work remotely with clients in other countries.

Q: Can you build something specific to our process?
A: Yes. Through Next Page Technologies we build custom applications, mobile apps, portals and integrations, and customise Odoo and Twenty CRM, when your process needs something ready-made software cannot do.

Q: Does it work on mobile?
A: Yes. The owner dashboard, approvals, wastage entry, stock checks, dispatch proof and alerts all work on mobile. Alerts and daily summaries can come on WhatsApp.

Q: Who is behind zappy.day?
A: zappy.day is built by Next Page Technologies Pvt. Ltd., a Hyderabad-based software company incorporated in 2016 and led by Founder and CEO Reddy Prasad Puligundla. The leadership has 16+ years of technology experience, 200+ projects delivered, and clients from ₹1 Cr to ₹100+ Cr turnover across 5+ countries.

## Optional
- [How we work](https://zappy.day/how-we-work)
- [About](https://zappy.day/about)
- [Contact](https://zappy.day/contact)