SaaS
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.
- Client
- Printed Carpet Manufacturer
- Year
- 2026
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 used
- Next.js
- PostgreSQL
- Nesting Algoritması
- Binary Format Tersine Mühendislik
- Kotlin
What would a system like this do for you?
We audit your ad account and site, then hand you a written roadmap in five business days.