Pulp and Paper MES vs ERP: What Does Your Mill Need?

 

ERP systems play an essential role in any company—especially when it comes to managing finance, procurement, and HR. Most pulp and paper mills already have one in place.

However, when it comes to the full breadth of manufacturing processes—such as execution, quality, and production reporting—ERP has its limitations. Mills need a modern manufacturing execution system (MES) to handle the complexity of pulp and paper operations.

But what about everything else a mill manages—like scheduling, trim optimization, shipping, and beyond? 

This is where mills face a crucial choice: customize ERP to take on these additional processes or extend a best-of-breed MES to handle them. 

For many mills, especially mid-sized operations, the modern MES path is faster, more flexible, and less costly to maintain. In this blog, we’ll look at three scenarios that often prompt mills to reexamine their approach——from mergers and acquisitions (M&A) to outdated systems that can’t keep up.

#1: Adopting MES Due to Mergers and Acquisitions

 

M&A activity often prompts mills to rapidly reevaluate their systems. Often, under a Transition Services Agreement (TSA), they face hard deadlines to migrate. Sometimes the pressure is cost-driven, with licensing renewals looming. Other times, companies want to consolidate all mills onto a common platform for better operational control.

Even if your company has historically relied on a monolithic ERP for processes like order management—and no longer wants to absorb that expense—it’s easy to shift those functions to a configurable MES like MAJIQ Elixir.

You can run order management and other extended processes on Elixir MES and integrate with a more cost-effective ERP for the finance and procurement side of the business. This is a popular route, particularly during mergers and acquisitions (M&A).

This was the case for Thunder Bay Pulp & Paper. Their acquisition triggered a critical timeline to replace a large legacy ERP in under a year, as required by their TSA. They required an end-to-end solution that could fully support operations, from orders to invoicing, without downtime. With the clock ticking, Thunder Bay turned to MAJIQ.

MAJIQ Elixir MES provided the reliability and functionality they needed. Furthermore, with such a tight deadline, the mill also needed in-person support to train staff and fast-track the transition. As John Nelson, VP of Transition, explained, “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.”

With hands-on guidance from MAJIQ’s pulp and paper experts, the team completed the transition within nine months—beating the original timeline and going live without production downtime.

The bottom line: M&A transitions are common in the pulp and paper industry—and when the pressure is on, you can't afford missteps. Industry-specific expertise, a proven implementation model, and hands-on support are what turn TSA deadlines from a major risk into a success story.

 

Mills moving off large, monolithic ERP systems often find that a best-of-breed MES, paired with a lighter ERP, offers greater flexibility, lower costs, and improved performance.

 

#2: Your MES is Outdated

 

Some companies find that their MES vendors aren’t keeping up with upgrades or updates. Over time, the system lacks performance and could even put the business at risk. 

With an outdated MES, you often end up with a web of ERP customizations or other workarounds—locking yourself into a system that can’t adapt or scale with your mill.

So, how do you know it’s time to make a change? A few signs include:

• Security risks: Without regular updates, your MES may be exposed to security gaps and vulnerabilities.
• No cloud option: Your current MES might restrict your options for improved flexibility, scalability, and security.
• Poor user experience: Younger workers may find your current system frustrating to learn and use.
• Lack of innovation: If your vendor only fixes problems but doesn’t improve the product, you’re missing out on better tools and features.

Another consideration is scalability—whether your MES can roll out to other mills or expand into new processes like warehouse and shipping. Outdated tech or over-customization often makes this impossible.

However, with a configurable, best-of-breed solution, this type of change is easy. For example, at Thunder Bay, we didn’t make any software changes. Because it was 100% configuration, MAJIQ was able to move at the speed of business.

In many cases, the right path forward is a modern, best-of-breed MES that’s purpose-built for pulp and paper, fully configurable, and ready to grow with your operation.

#3: Replacing a Legacy In-House System

 

Some mills realize they’ve outgrown the way they've always done things. They still rely on homegrown systems, cobbled together from outdated tools. As operations become more complex, these systems are prone to errors and unable to scale.

Modernization is no longer optional. As younger generations enter the workforce, sustainability pressures intensify, and the need for automation and data-driven decision-making increases, mills feel the pressure to adapt. 

That’s where a modern MES comes in. Rather than bolting ERP customizations onto outdated tools, a purpose-built MES gives you a cleaner, more scalable foundation. It helps streamline production, improve quality control, and provide real-time visibility into what's actually happening on the floor—all without adding unnecessary system complexity.

If your team is spending more time on data entry than decision-making, or if you're struggling to track inventory, monitor production, or generate consistent reports, now may be the right time to modernize with best-of-breed, pulp-and-paper-specific MES.

Making the Right Choice for Your Mill

 

If your systems are holding you back, a modern MES can help you move forward. It’s a strategic next step whether you’re replacing legacy tools, navigating an M&A transition, or taking steps to modernize.

The good news? You don’t have to overhaul everything overnight. MES can be rolled out in phases, starting where the impact is most immediate, or delivered ‘order-to-invoice’ from the start.

Look for a system that’s purpose-built for pulp and paper—and a partner that understands how your operations actually run. The right MES should strengthen your core execution layer and give you the flexibility to extend into areas like order management, scheduling, or logistics when needed—without relying on costly ERP customizations.

That’s where MAJIQ comes in. With more than 40+ years in the industry, we know what it takes to get MES right. Our proven approach helps mills implement Elixir MES on time and on budget, with support from industry experts who have in-depth knowledge of the pulp and paper industry.

Ready to explore your options? Reach out to our team here.