// SaaS & platforms · Printed Carpet Manufacturer
The expensive mistake is fabric — an in-house nesting engine
Designs are laid out on a roll before printing, and every square metre of gap is money burned. That layout was being done by eye in third-party software.
- 10–13%
- Less fabric consumed
- Search layer
- Best layout, not first feasible
- Barcode
- Labelling at every stage
Situation
In printed textile manufacturing, the expensive mistake is fabric.
The plant was doing layout by eye in third-party software and tracking production status on paper.
Approach
The tracking system came first, then the layout engine underneath it. Orders flow through defined stages with barcode-driven labelling, so a roll’s status is a fact rather than a phone call.
The nesting engine does placement in-house: a search layer explores candidate arrangements instead of taking the first feasible one.
The result is written straight into the printer’s own binary job format — which meant reverse-engineering that format, since no documentation exists.
Result
10–13% less fabric consumed on live orders.
Alongside it sit the systems that make the plant legible: a costing and scrap-rate module, dated pricing, and a native handheld app for the floor.
Technology
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