“Anytime we had an issue technical support was extraordinary at BatchMaster. It is hard for a software company to understand every industry they service, but the BatchMaster team was quick and open to learn.”

Kal Zucker

CIO and Co-Owner

Kalcor Coatings

Customer

Kalcor Coatings

Industry

Paints and Coatings

Location

Willoughby, OH

Solution

BatchMaster with SAP Business One

Systems Replaced

Proprietary In-House Applications

Kalcor Coatings Supports Growth and Modernizes Operations with BatchMaster ERP

For more than 60 years, Kalcor Coatings has manufactured specialty coatings and paints for the construction, transportation, fabricated metal, tire manufacturing, and graphic arts industries. From its Ohio-based manufacturing facility, the company develops custom formulations for customers throughout North America, Europe, and Asia.

As Kalcor continued to grow and expand its operations, the company recognized that its internally developed software applications could no longer support the increasing complexity of its manufacturing, formulation, inventory, and warehousing processes.

To modernize operations and support future growth, Kalcor selected BatchMaster ERP with SAP Business One as its process manufacturing ERP solution.

Challenges

Before implementing BatchMaster, Kalcor relied on a series of proprietary applications for inventory management, formulation, and production tracking.

1. Outgrowing Legacy Systems

As the business expanded, Kalcor needed a more scalable ERP platform to support more efficient plant operations, reporting, and process management.

2. Limited Visibility and Reporting

The company required stronger reporting and analytics capabilities to gain better operational insights and support business growth.

3. Managing Complex Formulations and Costing

Kalcor’s custom formulation business required accurate formula management, quality testing, and finished goods costing to respond quickly to customer requirements.

4. Preparing for Mobile and Integrated Warehousing

The company also wanted to modernize warehouse operations with mobile functionality, improved integrations, and wireless warehouse capabilities.

Solution

After evaluating several ERP vendors with experience in the paints and coatings industry, Kalcor selected BatchMaster because it best aligned with the company’s current and future operational needs.

In 2016, Kalcor implemented BatchMaster ERP for Paints & Coatings, built on SAP Business One.

The solution provided integrated functionality for:

Formula and recipe management
Inventory and warehouse management
Quality control testing
Production and batch management
Reporting and analytics
Mobile warehouse operations
Third-party software integrations

Kalcor also leveraged Crystal Reports to customize reports and dashboards, providing users with deeper operational insights across the business.

Key Results

1. Improved Formulation Management and Cost Visibility

BatchMaster’s Formulation module enabled Kalcor’s laboratory teams to develop and adjust formulas based on target physical properties, including VOC levels, density, water repellency, solar reflectance, and emissivity.

The system also calculates estimated finished-goods costs based on raw materials, labor, shipping, and landed costs, helping sales teams respond more quickly and accurately to customer inquiries.

2. Enhanced Reporting and Business Insights

With BatchMaster’s reporting and analytics capabilities, Kalcor gained greater visibility into operational performance and business trends.

Role-based dashboards, customized reports, and drill-down functionality helped management uncover optimization opportunities and make more informed decisions.

3. Stronger User Adoption and Ease of Use

Kalcor found BatchMaster intuitive for users, helping simplify onboarding and daily operations.

Features such as screen drill-down functionality and customizable menus allowed employees to access supporting information quickly and efficiently.

4. Exceptional Vendor Support and Collaboration

Kalcor highlighted BatchMaster’s responsiveness and partnership approach as a major contributor to implementation success and long-term satisfaction.

“Anytime we had an issue, technical support was extraordinary at BatchMaster,” explained Kal Zucker. “The BatchMaster team was quick and open to learning.”

As Kalcor evolved, BatchMaster continued working closely with the company to improve project plans, expand functionality, and support industry-specific needs.

5. Modernized Warehouse and Integration Capabilities

After seven years of success with BatchMaster, Kalcor upgraded its ERP environment to support mobile warehousing, improved platform compatibility, and stronger system integrations.

Using BatchMaster’s Mobile WMS functionality, warehouse teams can now execute receiving, putaway, picking, shipping, QC testing, and inventory adjustments using scan guns and smart tablets in a wireless warehouse environment.

Kalcor also expanded integration capabilities with Salesforce, ecommerce platforms, EDI systems, and SDS management solutions.

Looking Ahead

With BatchMaster ERP and SAP Business One in place, Kalcor Coatings is positioned to continue growing while improving operational visibility, customer service, and warehouse efficiency.

The company plans to further leverage BatchMaster’s advanced R&D, integration, and mobile warehouse capabilities to support innovation, streamline processes, and maintain its competitive advantage in the coatings industry.

About BatchMaster Software

BatchMaster Software is a leading provider of ERP solutions that help growing formula-based manufacturers streamline operations, reduce costs, and comply with stringent regulatory mandates. BatchMaster ERP is designed specifically for the Food, Nutraceuticals, Cosmetics, Pharmaceuticals, Chemicals, and Specialty Manufacturing industries, and can be deployed on-premise or in the cloud.