What is Pulp and Paper MES, and How Does It Drive Transformation?

The pulp and paper industry faces constant pressure to optimize efficiency, reduce waste, and maintain quality while adapting to an evolving market. 

Manufacturing Execution Systems (MES) have emerged as critical tools in this transformation journey. By bridging the gap between enterprise resource planning (ERP) systems and shop-floor operations, a Pulp and Paper MES enables real-time visibility, process automation, and seamless coordination across production, inventory, and logistics. 

But not all MES solutions are built the same — pulp and paper manufacturing has unique requirements that demand industry-specific capabilities.

This piece will explain what Pulp and Paper MES software is, how it helps transform manufacturing operations, and how to choose the right options for your business. Whether you're replacing a legacy system, navigating post-merger integration, or implementing your first MES solution, understanding these core concepts will help you make informed decisions that impact your mill's profitability and future growth.

 

What is Pulp and Paper MES?

Pulp and Paper MES is specialized software designed for pulp and paper mills. It connects business planning systems to actual production equipment on the factory floor. This system delivers real-time data, automates processes, and creates standard workflows so that production runs smoothly with less waste.

For paper mills specifically, MES helps manage the non-stop manufacturing process. It provides visibility throughout production—from pulp making to shipping. The system tracks important paper qualities like weight, moisture, thickness, and brightness while machines run at high speeds.

 

The Core Functions of an MES

According to Michael McClellan, author of "Applying Manufacturing Execution Systems," an MES delivers seven core functions that support manufacturing operations:

Planning System Interface:

Enables two-way communication between the MES and ERP systems, ensuring production orders flow to the shop floor while actual production data flows back to business systems. For paper mills, this synchronization optimizes inventory and aligns production with market demands.

Production Orders:

Automates electronic and manual order entries, adjusting in real time to meet production demands. This allows mills to respond quickly to changing customer requirements, modify production plans, and prioritize orders based on business needs without disrupting operations.

Work Stations:

For mills with converting or finishing operations like sheeting, off-machine coating, or tissue converting, MES functionality ensures the right materials, specs, and instructions reach each area at the right time. This coordination improves efficiency, maintains product quality, and keeps production running smoothly.

Inventory Tracking and Management:

Monitors the location and status of raw materials, work-in-progress (WIP), and finished goods across warehouses and production lines. In converting operations, this often includes packaging materials and coating chemicals, where effective inventory tracking helps reduce waste, ensure availability, and support cost control.

Material Movement:

Tracks where materials are throughout production. The system shows you where everything is—from raw materials to finished  products. The system tracks: 

• Raw materials as they arrive, get tested for quality, and move into production
• Large parent rolls moving from paper machines to cutting and converting areas
• Finished products moving to warehouses with proper grade and customer classifications
• Products transferring between different mill locations with appropriate documentation
• Packaging items like cores and pallets that need to be returned and reused

Effective material movement tracking reduces search time, prevents misplaced inventory, and ensures FIFO (first-in, first-out) principles are maintained for optimal product freshness.

Lineage

The MES tracks the lineage of where products come from by linking raw materials to batches, rolls to their source reels, and converted products like coated rolls or sheets back to their origin. This full traceability ensures that every finished item can be traced to its inputs and quality metrics, supporting quality control, compliance, and process improvement.

Data Collection

Gathers and organizes real-time production data for better decision-making and regulatory compliance. This function serves as the foundation for analytics, reporting, and continuous improvement initiatives.

Exception Management

Identifies problems like equipment malfunctions, missing materials, or process issues so they can be fixed quickly. The system sends instant alerts and provides step-by-step instructions so workers can solve problems before production suffers. In paper mills, common urgent issues include:

• Quality parameter deviations that could result in off-grade production
• Raw material shortages that might affect production scheduling
• Logistics disruptions affecting incoming or outgoing shipments

Good exception management doesn't just find problems. It suggests solutions, tells workers who to contact when needed, and tracks fixes to stop issues from coming back.

 

Who Needs Pulp and Paper MES?

Not every mill has the same operational challenges, but most will reach a point where an MES becomes necessary. Mills that fall into the following categories will benefit the most from implementing a Pulp and Paper MES:

Mills Replacing Legacy Systems

Many mills still rely on in-house systems that were built for a different era. While these systems may still function, they often fall short when it comes to adapting to modern security standards, evolving business requirements, and the expectations of a new generation of workers. They can be difficult to train on, hard to support, and pose growing risks as technology and cybersecurity needs continue to advance.

Mills Transitioning Due to Mergers & Acquisitions

When companies merge, they end up with many different systems that don't work well together. As businesses combine, they often need to move away from inflexible, expensive ERP systems. An MES helps unify operations, create standard processes, and make the transition smoother.

Mills Implementing MES for the First Time

Some mills have never used an MES before, but as they scale or modernize, their needs evolve. These operations historically rely on spreadsheets, paper records, or basic ERP functionality to manage production. As they grow, they need a purpose-built solution to enhance production efficiency and quality control. 

A Pulp and Paper MES is more than a software upgrade. Mills across a variety of circumstances can turn to an MES to solve critical business problems.

How MES Integrates and Connects Manufacuring Operations

A modern MES is the backbone of a connected factory. To run efficiently, manufacturers need a solution that seamlessly integrates with critical business systems—such as ERP, quality management, and supply chain platforms—while also connecting people, machines, and real-time data. A well-integrated MES reduces complexity, eliminates redundant systems, and ensures smooth operations across the entire production lifecycle.  

With the right MES, manufacturers can streamline operations and avoid the inefficiencies of disconnected tools. Key integration areas include: 

Logistics Management

MES software helps coordinate material flow, track deliveries, and optimize supply chain efficiency to prevent bottlenecks and ensure timely production

Inventory and Warehousing

By integrating with warehouse management systems, MES enables real-time inventory tracking, reducing waste and ensuring optimal material usage. 

Production Planning

MES integrates with ERP and scheduling systems to align production with demand forecasts, optimize capacity utilization, and minimize downtime. 

Customer Service and Invoicing

An MES enhances order accuracy, provides real-time production tracking, and ensures a smooth transition from manufacturing to fulfillment and invoicing, improving customer satisfaction.  

By bridging the gap between systems, machines, and operations, an MES empowers manufacturers with the visibility and control needed to optimize production, improve efficiency, and drive continuous improvement—without unnecessary complexity or technical debt.

 

What Other MES Capabilities Are Essential for Pulp and Paper Mills?

Pulp and paper manufacturers need more than basic MES functions—they require industry-specific capabilities built for the unique complexities of paper production. These specialized features drive efficiency, reduce waste, and improve product quality beyond the basic MES.

Trim Optimization and Waste Reduction

Advanced algorithms find the best way to use materials, reducing waste and making more sellable products. This matters a lot in paper production, where cutting large rolls efficiently saves money. Today's trim systems consider customer order priorities, machine capabilities, paper grade changes, and shipping constraints to make the mill more efficient.

Label Printing and Tracking

Labeling tools create accurate product tags and track items from production to delivery. In the pulp and paper industry, proper labeling is essential for inventory management, customer satisfaction, and regulatory compliance. Label printing capabilities are particularly crucial for mills that supply customers with specific labeling requirements or that ship globally with multiple language needs.

Advanced labeling capabilities include:

• Automatic generation of customer-specific labels with customizable fields
• Barcode or RFID integration for automated tracking throughout the supply chain
• Multi-language support for global operations and international shipping
• Integration with production data for accurate product specifications on each label
• Compliance with industry standards and customer requirements for label content
• Support for multiple label formats and printers across different production areas

Quality Management

MES systems help mills maintain consistent quality by monitoring both machine-direction and cross-direction sheet properties in real time. The system captures scan test results, along with manual and automated checks, and alerts operators when values drift outside customer specs. This is critical during grade changes, where sheet characteristics can shift quickly. By detecting issues early, mills can reduce waste, avoid defects, and ensure products meet customer and regulatory requirements.

Make-to-Order Capabilities

Custom order processing and make-to-order systems help mills meet special customer needs efficiently. As markets demand more customized products delivered faster, make-to-order capabilities let mills manage special product specifications while balancing custom orders with regular production runs.

Some mills may already run software with some of these capabilities, but when they all work together, the result can be greater than the sum of their parts.

How Does Pulp and Paper Software like MES Help Manufacturers Transform Operations?

With an understanding of what MES is and its essential capabilities, the next question is: What benefits does it bring to paper mills? A good Pulp and Paper MES improves efficiency, production quality, and business outcomes:

Enhances Production Planning

MES systems adjust schedules in real time, optimizing production. This changes planning from periodic and reactive to continuous and dynamic, cutting changeover time and waste while getting more from machines.

Automates Processes

Reducing manual interventions increases accuracy and reduces labor costs. Process automation transforms operations by standardizing best practices and removing variability, resulting in consistent execution of procedures and reduced error rates.

Ensures Product Quality

Continuous quality monitoring and automated alerts help mills maintain high standards. Quality management transforms from a reactive inspection process to a proactive system that prevents defects through early detection and intervention.

Streamlines Supply Chain Management

Better coordination between suppliers, production, and shipping improves on-time deliveries. This turns disconnected processes into a synchronized flow of materials and information, reducing inventory while improving delivery.

Delivers Real-Time Data for Business Intelligence

Actionable insights drive better decision-making at all levels of the organization. This moves operations from gut-feel management to data-driven decision-making, with dashboards providing role-specific information and analytics identifying patterns and improvement opportunities.

Supports Regulatory Tracking and Compliance

Built-in tools help meet environmental and safety regulations. Compliance shifts from manual paperwork to automatic documentation, reducing violation risks and making audits easier. By using these capabilities, paper mills can work more efficiently, meet regulations, and better satisfy customers while becoming more responsive and adaptable.

 

How Can You Choose the Right Pulp and Paper Industry Software?

Once the benefits of implementing a Pulp and Paper industry software like MES are clear, the challenge becomes selecting the right solution for your specific needs. With various providers and approaches available, making an informed decision requires understanding key differentiators. Selecting the ideal MES solution for your pulp and paper operation requires careful consideration of your current needs, future goals, and the specific capabilities that will deliver the most value.

MES Footprint Options

Choosing the right Pulp and Paper MES depends on the specific operational needs of a mill. There are three primary MES models to consider:

Order-to-Invoice MES

A comprehensive solution covering the full production cycle from order management to final invoicing. This model is ideal for organizations looking to streamline the entire business process with a single integrated solution, providing end-to-end visibility and control.

This option works best for:

• Mills seeking to replace multiple legacy systems with a single solution
• Operations focused on customer service and order fulfillment excellence
• Organizations with limited IT resources that prefer a single vendor

Manufacturing Operations Management (MOM) MES

Focuses on plant-wide execution, including scheduling, inventory, and real-time process control. This model concentrates on optimizing shop floor operations while integrating with existing enterprise systems for business functions.

It's best suited for:

• Mills with established ERP systems that need enhanced shop floor capabilities
• Operations prioritizing production efficiency and equipment effectiveness
• Organizations with complex manufacturing processes requiring specialized control

Small Footprint MES for Large ERP

Provides targeted MES functionality while integrating with a larger ERP system to minimize redundancy. This approach extends ERP capabilities with specific manufacturing functionality not available in the core ERP.

It works well for:

• Organizations heavily invested in a comprehensive ERP platform
• Mills looking to address specific operational gaps without replacing existing systems
• Operations with standardized processes that need limited customization

Selecting the right model ensures alignment with business goals and operational complexity, providing the foundation for a successful implementation.

Purpose-Built for Pulp and Paper

Choosing an MES that is specifically designed for the pulp and paper industry is essential for maximizing efficiency and achieving long-term success. A purpose-built Pulp and Paper MES offers:

• Industry-Specific Functionality

  • Are there tailored features designed to handle the complexities of roll, sheet, and bale production? Generic MES solutions often require extensive customization to address pulp and paper manufacturing requirements, leading to higher implementation costs and ongoing maintenance challenges.

• Proven Reliability

  • Is it trusted by leading mills to enhance efficiency and streamline operations? With unplanned downtime costs ranging from $80,000 to $150,000 per hour, according to Paper360° (TAPPI), the financial impact of inefficiency is substantial—which means it’s critical to choose the right MES. Purpose-built solutions have weathered the specific challenges of pulp and paper manufacturing and evolved to address them effectively.

• Configurable Workflows

  • Do the solutions fit seamlessly within existing pulp and paper manufacturing processes? Pulp and Paper MES systems that deliver best practices out-of-the-box help mills hit the ground running with proven processes. Configurable solutions bring the added benefit of helping customers easily adapt to their unique processes.

Ability to Manage Various Product Types

A robust Pulp and Paper MES should be capable of handling diverse product types, including pulp, fine paper, packaging, and specialty grades. 

As an added benefit, some Pulp and Paper MES systems support black liquor processing, a byproduct in kraft pulping operations. 

This versatility is essential for integrated mills that produce multiple product types, organizations that may diversify their product mix, and operations that need to track and monetize byproducts.

Scalability to Meet Evolving Challenges

The pulp and paper industry is continuously evolving, and mills must be prepared to adapt long-term. From aging infrastructure to workforce challenges and increasing sustainability demands, mills must navigate complex operational demands to remain competitive.

The pulp and paper industry is constantly evolving, requiring mills to stay agile and future-ready. Aging equipment, shifting workforce expectations, and growing sustainability demands all add new challenges. As experienced workers retire, it’s essential to capture their knowledge and automate processes to maintain efficiency. At the same time, younger workers expect modern, user-friendly systems. Stricter sustainability regulations also require mills to reduce waste and optimize resources. Choosing a pulp and paper MES built by industry experts—with scalability and continuous upgrades—ensures mills can adapt to whatever comes next.

Is Your Business Ready for Pulp and Paper MES?

After understanding what MES is, its capabilities, benefits, and selection criteria, the natural question becomes: Is your operation ready to take this step? Determining if your operation is ready for a Pulp and Paper MES implementation requires an honest assessment of your current capabilities, pain points, and readiness for change.

Understanding Your Needs

To determine if your business is ready for a Pulp and Paper MES, consider these key questions:

• Do you lack visibility into your operations or data for informed decision-making? If your management team frequently struggles to get timely, accurate information about production status, inventory levels, or quality metrics, an MES can provide the real-time visibility needed for effective decision-making. 
• Are your production processes hindered by inefficiencies or outdated manual workflows? If operators spend significant time on data entry, paperwork, or manual calculations, an MES can automate these tasks and free up valuable time for more value-added activities. 
• Are you struggling to meet sustainability goals or regulatory requirements? If compliance reporting is cumbersome, time-consuming, or prone to errors, an MES can automate data collection and reporting, ensuring accurate and timely compliance.

If you answered yes to any of these questions, your operation could benefit significantly from implementing a Pulp and Paper MES.

Knowing What to Expect During MES Implementation

When implementing an MES, it’s important to ensure minimal disruption to ongoing operations. 

The implementation process generally involves these key phases:

• Assessment and Planning — Process mapping, gap analysis, and implementation roadmap creation
• Configuration and Development — System setup, integration with existing systems, and data migration
• Testing and Validation — Unit testing, integration testing, and user acceptance testing
• Training and Deployment — User training, pilot deployment, and phased rollout
• Optimization and Expansion — Performance monitoring, user feedback collection, and continuous improvement

How Long Does Implementation Take?

A purpose-built pulp and paper MES implementation, delivered by industry experts, can average 9 months—a much quicker timeframe than generic MES or highly customized solutions. 

For example, Thunder Bay Mill successfully transitioned from SAP to Elixir in just six months, meeting their ambitious deadline without production downtime.

When Thunder Bay needed in-person guidance to train staff and fast-track the transition process, MAJIQ provided personalized, on-site training that made a critical difference for their small implementation team. The MAJIQ team was able to deliver the important project on budget and within a tight timeline. 

"We felt confident that MAJIQ would give us a proven solution with a seamless transition, while also saving cost. However, it was also the in-person training that changed the game for our team. Because of our tight timeline, the personalized support and deep industry expertise made all the difference." - John Nelson, Thunder Bay VP of Transition

Evaluating MES Software Providers: Questions to Ask

When exploring industry-specific MES solutions that align with your needs, the following categories of questions can help you evaluate whether a particular software provider is right for your operation:

Industry Experience & Expertise

• How much industry-specific experience does your implementation team have in pulp and paper?
• Can you provide references from other pulp and paper manufacturers with similar operations, whether with local operations or globally?

System Architecture & Integration

• Is your software fully integrated, or does it require multiple modules purchased separately?
• What is your approach to integrating with legacy systems during transition periods?

Implementation & Support

• What type of customer support do you offer? 
• How do you ensure system stability for continuous 24/7 paper machine operations?

Future-Proofing & Innovation

• How do you handle software updates and how frequently are they released?
• What percentage of your customers are on the latest version of your software?

These questions will help you assess not only the technical capabilities of the MES solution but also the provider's understanding of pulp and paper manufacturing and their commitment to partnership.

 

Transforming Mill Operations with Pulp and Paper MES and MAJIQ Expertise

A Pulp and Paper MES is a powerful tool that improves efficiency, quality, and sustainable growth. Selecting the right system optimizes mill operations by providing real-time visibility, process automation, and data-driven decision support.As the pulp and paper industry continues to face challenges from aging infrastructure, workforce transitions, and increasing competitive pressures, a purpose-built MES becomes more of a strategic necessity than a nice-to-have tool. The right solution delivers immediate operational improvements while building the foundation for ongoing optimization.

MAJIQ stands out as a trusted provider in this space, offering industry-specific solutions built on 40+ years of pulp and paper expertise. MAJIQ team members average 20 years of experience in the industry, enabling them to deliver reliable, on-time, and on-budget implementations. The MAJIQ Elixir MES platform delivers purpose-built functionality with the reliability, scalability, and support that modern mills require.

Whether you're just beginning to explore what a Pulp and Paper MES can do for your operation or you're ready to take the next step in your digital transformation journey, industry experts can help guide you through the process. No matter where you are in your journey to operational excellence, the right MES partner will understand your unique challenges, provide industry best practices, and support your operation's growth and evolution for years to come.

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